Installation (2001 Intrigue)
NOTE:
Internal components of this booster are not serviceable. The housing must not be unstaked and separated. Separating the housing will cause permanent deformation, preventing the booster from holding proper volume.
IMPORTANT:
Inspect the locking flanges on booster and mounting plate. Replace the booster and mounting plate if the locking flanges are bent or damaged.
IMPORTANT:
Carefully push the pushrod eye through the hole so that you do not damage or dislodge the insulator boot.
- Install the vacuum brake booster.
- Position the vacuum brake booster on the cowl counterclockwise from the final installation position so that the locking flanges on the vacuum brake booster and on the cowl mounting flange engage.
IMPORTANT: Ensure that the locking tab and the flanges are in the fully engaged position.
- Turn the vacuum brake booster clockwise with a ratchet on the J 22805-B (2). DO NOT use a flat bladed tool in the locking tab to install the vacuum brake booster. When the vacuum brake booster is correctly installed, the locking tab (1) slides up the flange and engages the locking notch.
- Remove the J 22805-B (2) from the installed vacuum brake booster.
- Install the coolant bypass pipe.
- Reconnect the coolant bypass hose.
- Install the EGR valve.
- Install the brake pressure modulator valve (BPMV) bracket.
- Install the vacuum hose to the vacuum brake booster.
- Install the brake pressure modulator valve. Refer to BRAKE PRESSURE MODULATOR VALVE .
- Install the master cylinder. Refer to MASTER CYLINDER Removal & Installation .
- Install the vacuum hose and booster check valve to the brake booster.
- Connect the EVAP canister purge valve pipe, the fuel feed and return pipe.
- Install the fuel injector sight shield.
- Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM .
- Connect the vacuum brake booster pushrod to the brake pedal and install the retaining clip.
- Install the left instrument panel insulator.
- Connect the negative battery cable.