GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Aveo 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Power Vacuum Brake Booster Replacement

Removal Procedure

    Object Number: 1245647 Size: SH
  1. Disconnect the electrical connector from the reservoir.

    2. Object Number: 1245654 Size: SH
  2. For vehicles with a manual transaxle, disconnect the clip on the clutch hose connection to the master cylinder.
  3. Plug the clutch hose and the master cylinder so that the fluid does not escape.

    4. Object Number: 1245651 Size: SH
  4. Remove the master cylinder attaching nuts.
  5. Push the master cylinder forward slightly and move it out of the way. Do not disconnect the brake lines.
  6. Remove and discard the booster housing seal.

    7. Object Number: 1245655 Size: SH
  7. Remove the clip on the vacuum hose connection to the booster, DOHC engine connection shown.
  8. Disconnect the brake lamp switch.
  9. Remove the brake pedal spring.
  10. Disconnect the clip and the pushrod pin from the pedal bracket assembly. Refer to Brake Pedal Assembly Replacement .

    11. Object Number: 1245656 Size: SH
  11. Remove the booster and the support bracket-to-dash panel nuts.

    12. Object Number: 1245654 Size: SH
  12. Remove the booster and the bracket assembly from the dash panel.

    13. Object Number: 1245657 Size: SH
  13. Remove the bracket nuts from the booster and remove the booster.

    14. Object Number: 1245658 Size: SH
  14. Remove the rubber boot and the retainer.

    15. Object Number: 1245661 Size: SH
  15. Remove the pushrod.
  16. Remove the adjustment sleeve from the pushrod.
  17. Remove the hex nut.

Installation Procedure

    Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.


    Object Number: 1245663 Size: SH
  1. Inspect the pushrod and the adjustment sleeve for damage and proper fit.

    2. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1245661 Size: SH
  2. Install the hex nut and the adjustment sleeve on the booster.

    3. Tighten
    Tighten the booster pushrod hex nut and the adjustment sleeve to 16 N·m (12 lb ft).


    Object Number: 1245653 Size: SH
  3. Insert the pushrod in the adjustment sleeve and mount the retainer.

    4. Important: This measurement (a) should be 278.5  mm (10 in).

  4. Measure the distance from the booster to the center of the fork bin bore.

    5. Object Number: 1245658 Size: SH
  5. Install the rubber boot on the booster.

    6. Object Number: 1245657 Size: SH
  6. Install the brackets to the booster.

    7. Tighten
    Tighten the booster-to-support bracket nuts to 12 N·m (9 lb ft).


    Object Number: 1245654 Size: SH
  7. Install the booster and the bracket assembly to the dash panel.

    8. Tighten
    Tighten the booster and support bracket-to-dash panel nuts to 24 N·m (18 lb ft).


    Object Number: 1245657 Size: SH
  8. Connect the master cylinder to the booster and install a new booster housing seal.

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


    Object Number: 1245655 Size: SH
  9. Install the new vacuum hose to the booster, DOHC engine connection shown. Refer to Vacuum Brake Booster Check Valve and/or Hose Replacement .
  10. Install new hose clamps on the vacuum hose.
  11. Install the pushrod pin to the brake pedal bracket assembly and connect the clip and the spring. Refer to Brake Pedal Assembly Replacement .
  12. Install the brake lamp switch.