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Vacuum Booster (1999-2001): Installation

  1. Install vacuum booster on dash panel using reverse procedure of its removal. Install 4 nuts mounting vacuum booster to dash panel. Tighten mounting nuts to 23 N.m (200 INCH lbs.). Install wiring harness junction connector bracket on right hand side mounting studs of vacuum booster. Tighten mounting nuts to 29 N.m (250 INCH lbs.). Using lubricate, or an equivalent, coat brake pedal pin where it contacts vacuum booster input rod.
    NOTE: When installing vacuum booster input rod on brake pedal pin input rod must be positioned as shown in illustration. See Figure . The chamfer on vacuum booster input rod must facing brake pedal arm when installed on brake pedal pin. The retaining clip must be installed on flat side of vacuum booster input rod.
    CAUTION: When installing brake pedal pin on vacuum booster input rod, do not re-use old retaining clip.
  2. Install input rod for vacuum booster on brake pedal pin. Install a NEW retaining clip on brake pedal pin. See Figure . The retaining clip must be installed on flat side of vacuum booster input rod. See Figure . Install knee blocker trim panel. Connect vacuum hose on check valve in vacuum booster and vacuum fitting in intake manifold.
    CAUTION: The master cylinder is used to create seal for holding vacuum in vacuum booster. The vacuum seal on master cylinder MUST be replaced with a NEW seal whenever master cylinder is removed from vacuum booster. When removing vacuum seal from master cylinder DO NOT use a sharp tool.
  3. Using a soft tool such as a trim stick, remove vacuum seal from master cylinder mounting flange. Install a NEW vacuum seal on mounting flange of master cylinder. See Figure . Position master cylinder on vacuum booster, aligning push rod on vacuum booster with master cylinder piston.
  4. Install 2 nuts mounting master cylinder to vacuum booster tighten both mounting nuts to 25 N.m (225 INCH lbs.). See Figure . Connect brake tubes to master cylinder primary and secondary ports. See Figure . Tighten fittings to 17 N.m (145 INCH lbs.). Install 2 structural support struts. Securely tighten support strut attaching nuts and bolts. Check operation of stop lamp switch and adjust if necessary.
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