Power Booster Assembly Removal and Installation: Installation

Check the pushrod and the pushrod clevis for damage and proper fit.
Install the hex nut and the pushrod clevis on the booster shaft.
Tighten

Tighten the booster hex nut and the pushrod clevis to 18 N.m (13 lb-ft).

Fig 1: Tightening Booster Hex Nut
Courtesy of SUZUKI OF AMERICA CORP.
Measure the distance from the booster to the center of the fork pin bore and install the rubber boot on the booster.
NOTE: This measurement should be 120 mm (4.7 inches).

Fig 2: Identifying Distance From Booster To Center Of Fork Pin Bore
Courtesy of SUZUKI OF AMERICA CORP.
Install the booster and the mounting nuts to the dash panel.
Tighten

Tighten the booster-to-dash panel nuts to 22 N.m (16 lb-ft).

Fig 3: Installing Booster And Mounting Nuts To Dash Panel
Courtesy of SUZUKI OF AMERICA CORP.
Attach the shaft and the rubber O-ring.
Connect the master cylinder to the booster. Refer to "MASTER CYLINDER ASSEMBLY REMOVAL AND INSTALLATION :"
Connect the brake line fittings to the hydraulic modulator, if applicable.
Tighten

Tighten the brake line fittings to 16 N.m (12 lb-ft).

Tighten

Tighten the master cylinder attaching nuts to 24 N.m (18 lb-ft).

Fig 4: Connecting Brake Line Fittings To Hydraulic Modulator
Courtesy of SUZUKI OF AMERICA CORP.
Install the new vacuum hose to the booster. Refer to "VACUUM HOSE REMOVAL AND INSTALLATION :".
Install the hose clamps on the vacuum hose, and snap the vacuum hose in the revolving clip.
Install the pushrod pin to the brake pedal bracket assembly and connect the clip and the spring. Refer to "BRAKE PEDAL REMOVAL AND INSTALLATION :".
Install the brake stoplamp switch. Refer to "STOPLAMP SWITCH REMOVAL AND INSTALLATION :".

Fig 5: [Installing Vacuum Hose To Booster]
Courtesy of SUZUKI OF AMERICA CORP.