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

Removal Procedure
  1. Apply and release the brake pedal several times until it becomes firm to deplete the brake booster vacuum reserve.
  2. Disconnect the vacuum power brake vacuum sensor electrical connector, if equipped.
  3. Remove the vacuum power brake booster check valve and hose assembly from the brake booster grommet.
  4. Remove the underhood electrical center and bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement.
  5. Remove the master cylinder. Refer to Master Cylinder Replacement.

    6. Object Number: 1912299 Size: SH
  6. Remove the brake pedal pushrod nut (1).

    7. Object Number: 1912300 Size: SH
  7. Remove the brake pedal pushrod washer (1).
  8. Remove the brake pedal pushrod from the brake pedal pivot pin.

    9. Object Number: 1912303 Size: SH
  9. Remove the vacuum brake booster nuts (1).

    10. Object Number: 1912326 Size: SH
  10. Remove the power brake vacuum booster (1).

    11. Object Number: 1912328 Size: SH
  11. Remove the power brake vacuum booster gasket (1).

    12. Inspect the power brake vacuum booster gasket for damage and replace if necessary.

Installation Procedure

    Object Number: 1912328 Size: SH
  1. Install the power brake vacuum booster gasket (1).

    2. Object Number: 1912326 Size: SH
  2. Install the power brake vacuum booster (1).

    3. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1912303 Size: SH
  3. Install the vacuum brake booster nuts (1).

    4. Tighten
    Tighten the nuts to 17 N·m (14 lb ft).


    Object Number: 1912300 Size: SH
  4. Apply a thin coating of high temperature grease GM P/N 12345996 (Canadian P/N 10953501) to the pushrod pin on the brake pedal.
  5. Connect the brake pedal pushrod to the brake pedal pivot pin.
  6. Install the brake pedal pushrod washer (1).

    7. Object Number: 1912299 Size: SH
  7. Install the brake pedal pushrod nut (1).

    8. Tighten
    Tighten the nut to 10 N·m (89 lb in).

  8. Install the vacuum power brake booster check valve and hose assembly to the brake booster grommet.

    9. If necessary, a small amount of denatured alcohol can be used as an assembly aid for installing the check valve and hose assembly to the vacuum booster grommet. Do not use soap.

  9. Connect the vacuum power brake vacuum sensor electrical connector, if equipped.
  10. Install the master cylinder. Refer to Master Cylinder Replacement.
  11. Install the underhood electrical center and bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement.