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: Installing Pushrod Clevis On Booster Shaft
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.
See Figure.
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 2: Identifying Booster-To-Dash Panel Nuts
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 the master cylinder attaching nuts to 24 N.m (18 lb-ft).
  See Figure.
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 .
See Figure.