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Home >> Saturn >> 2003 >> Ion 1 Standard >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Disc Brakes & Drum Brakes >> Removal & Installation >> Vacuum Booster (Vehicles Equipped With CVT) >> Installation

Vacuum Booster (Vehicles Equipped With CVT): Installation

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.
  1. Install mounting gasket to vacuum brake booster.
  2. Turn the booster to face the left strut tower.
  3. Ensure that the rear of the booster shell is clear of the valve body cover on top of the transmission.
  4. Rotate the booster, while it remains sideways to the firewall, and carefully install the booster down and rearward in between the cowl and transmission.
  5. With the booster directed toward the coolant surge tank, install the booster push rod into the opening in the firewall.
  6. Align brake booster to firewall, and insert booster studs through the dash.
  7. Loosely install brake booster mounting nuts.
  8. Apply a thin coating of lithium grease to the push rod pin on the brake pedal.
  9. Connect brake booster push rod to the brake pedal.
  10. Install washer and retaining clip to the brake pedal.
  11. Tighten vacuum brake booster mounting nuts to specification. See TORQUE SPECIFICATIONS .
  12. Install accelerator pedal into position and install pedal mounting nuts.
  13. Using engine support fixture, slowly raise transmission into the fully installed position.
  14. Carefully install the transmission side mount-to-transmission bolts by hand. DO NOT force the bolts.
  15. Using ONLY HAND TOOLS, Tighten transmission side mount-to-transmission bolts.
  16. With vehicle still positioned on the hoist, raise and support vehicle.
  17. Install heat shield and through-bolt to the rear transmission mount. Hand start the bolt. DO NOT tighten bolt.
  18. Install through-bolt to the front transmission mount. Hand start bolt. DO NOT tighten bolt.
  19. Tighten the rear bolt first and then the front bolt to specification. See TORQUE SPECIFICATIONS .
  20. Lower vehicle.
  21. Remove engine support fixture.
  22. Connect EVAP purge hose to purge solenoid.
    23. NOTE: A small amount of denatured alcohol can be used as an assembly aid when installing the vacuum check valve. DO NOT use soap.
  23. Connect vacuum check valve with hose to brake booster.
  24. Connect electrical connector to Park/Neutral Position switch.
  25. Ensure master cylinder-to-vacuum brake booster seal is properly seated into the recessed groove on the master cylinder.
  26. Install master cylinder and auxiliary reservoir, as an assembly, to vacuum brake booster.
  27. Install brake master cylinder mounting nuts. Tighten to specification. See TORQUE SPECIFICATIONS .
  28. Install brake master cylinder auxiliary reservoir mounting bolts. Tighten to specification.
  29. Secure master cylinder pipes to the 6-position pipe clip along the frame rail.
  30. Position master cylinder pipes to master cylinder ports.
  31. Remove caps from brake pipe ends.
  32. Connect brake pipe fittings at master cylinder. Tighten to specification. See TORQUE SPECIFICATIONS .
  33. Secure wiring harness retainer to the side of the left strut tower.
  34. Install wiring harness to the retainers above the brake booster, and secure the retainers.
  35. Install underhood electrical center bracket to vehicle and install the electrical center into position on the bracket.
  36. Secure the forward light harness retainer to the ABS modulator bracket, or the proportioning valve bracket.
  37. Connect electrical connector to brake fluid level sensor, then press forward on the CPA tab of the connector to secure.
  38. Install cover to the underhood electrical center.
  39. Connect negative battery.
  40. Bleed hydraulic brake system. See BLEEDING BRAKE SYSTEM .
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