GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2001 🢒 Bonneville 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Power Vacuum Brake Booster Replacement

Removal Procedure

    Object Number: 678819 Size: SH
  1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.8L.
  2. Remove the air inlet duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.8L.
  3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls -3.8L.
  4. Remove the accelerator control cable bracket and position the cables out of the way. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls - 3.8L.
  5. Remove the cruise control module (1) and position out of the way. Refer to Cruise Control Module Replacement in Cruise Control.
  6. Disconnect the engine electrical harness (2) at the left strut tower.

    7. Object Number: 707318 Size: SH
  7. Disconnect the electrical connector from the EGR valve (1).
  8. Disconnect the engine harness clips (3).
  9. Position the wiring harness (2) out of the way.

    10. Object Number: 675866 Size: SH
  10. Disconnect the brake fluid level sensor wire connector (1).

    11. Object Number: 420706 Size: SH
  11. Remove the master cylinder attaching nuts.
  12. Remove the master cylinder from the booster. and carefully position the master cylinder out of the way.
  13. Remove the vacuum brake booster check valve from the booster. Refer to Vacuum Brake Booster Check Valve and/or Hose Replacement .
  14. Remove the left closeout/insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel Gages and Console.
  15. Remove the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel Gages and Console.

    16. Object Number: 695567 Size: SH
  16. Remove the vacuum brake booster pushrod retainer (3) from the brake pedal clevis pin.
  17. Remove the foam spacer (2) from the brake pedal clevis pin.
  18. Disconnect the pushrod (1) from the brake pedal clevis pin.

    19. Object Number: 695564 Size: SH
  19. Remove the vacuum brake booster mounting nuts (1) from the brake pedal assembly.

    20. Object Number: 106322 Size: SH
  20. Remove the vacuum brake booster from the vehicle.
  21. Remove the brake booster mounting gasket, if gasket replacement is necessary.

Installation Procedure
  1. Install the brake booster mounting gasket to booster, if removed previously.

    2. Object Number: 106322 Size: SH
  2. Install the brake booster to the vehicle.

    3. Object Number: 695564 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Install the brake pedal assembly to booster stud mounting nuts (1).

    4. Tighten
    Tighten the brake pedal assembly to booster stud mounting nuts to 23 N·m (17 lb ft).

  4. Apply a small amount lubricant, (GM P/N 12346293) or equivalent to the clevis pin of the brake pedal.

    5. Object Number: 695567 Size: SH
  5. Connect the brake booster pushrod (1) to the brake pedal clevis pin.
  6. Install the foam spacer (2) to the brake pedal clevis pin.
  7. Install the booster pushrod retainer clip (3) to the brake pedal clevis pin.
  8. Install the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel Gages and Console.
  9. Install the left closeout/insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel Gages, and Console.

    10. Object Number: 420706 Size: SH
  10. Install the master cylinder onto the vacuum brake booster.
  11. Install the master cylinder mounting nuts. Refer to Master Cylinder Replacement .
  12. Install the vacuum brake booster check valve to the booster. Refer to Vacuum Brake Booster Check Valve and/or Hose Replacement .

    13. Object Number: 675866 Size: SH
  13. Connect the brake fluid level sensor wire connector (1).

    14. Object Number: 678819 Size: SH
  14. Install the cruise control module (1). Refer to Cruise Control Module Replacement in Cruise Control.
  15. Connect the electrical connector (2) to the left strut tower.

    16. Object Number: 707318 Size: SH
  16. Connect the electrical connector to the EGR valve (1).
  17. Connect the engine harness clips (3).
  18. Install the accelerator control cable bracket. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls - 3.8L.
  19. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement 1 in Engine Controls - 3.8L.
  20. Install the air inlet duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.8L.
  21. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.8L.