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

Power Vacuum Brake Booster Replacement 5.3L


Object Number: 1661276 Size: MF

Callout

Component Name

Preliminary Procedures

  1. Remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement.
  2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
  3. Remove the brake pressure modulator valve (BPMV) mounting bracket. Refer to Brake Pressure Modulator Valve Bracket Replacement.
  4. Remove the master cylinder assembly. Refer to Master Cylinder Replacement.
  5. Remove the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement.
  6. Disconnect the vacuum hose from the vacuum brake booster check valve.

1

Brake Booster Electrical Connector

2

Release Lever

3

Tool

Tip
Using the J 22805-B , remove the brake booster.

Special Tools

J 22805-B Brake Booster Holder

4

Brake Booster

Tip

    • It may be necessary to remove the retaining bolts for the coolant lines underneath the throttle body and at the front of the engine to relocate the coolant lines to remove the booster.
    • Bleed the brake system. Refer to Hydraulic Brake System Bleeding.

Power Vacuum Brake Booster Replacement 3.5L, 3.9L

Special Tools

J-22805-B Brake Booster Holder

Removal Procedure
  1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement for the 3.5L engine or Intake Manifold Cover Replacement for the 3.9L engine.
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement for the 3.5L engine or Air Cleaner Outlet Duct Replacement for the 3.9L engine.
  3. Without draining the engine coolant or disconnecting the heater hoses, remove the heater pipe assembly from the throttle body and position aside. Refer to Heater Pipes Replacement.
  4. Disconnect the brake fluid level switch electrical connector.

    5. Object Number: 1994002 Size: SH
  5. Disconnect the vacuum power brake booster check valve and hose assembly (1).
  6. Disconnect the vacuum power brake booster vacuum sensor electrical connector.

    7. Object Number: 1994005 Size: SH
  7. Remove the master cylinder nuts (1).
  8. Without disconnecting the brake pipes, remove and position aside the brake master cylinder.

    9. Secure the master cylinder with heavy mechanics wire or equivalent.

  9. Wrap a shop cloth around the inboard stud on the vacuum power brake booster to protect the stud threads.
  10. Install the  J-22805-B Brake Booster Holder to the opposite vacuum power brake booster stud and secure with a master cylinder nut.

    11. Object Number: 1994008 Size: SH
  11. Levering against the inboard power vacuum brake booster stud, press the vacuum power brake booster locking tab (1) and rotate the  J-22805-B Brake Booster Holder  (2) counter clockwise.
  12. Carefully pull the vacuum booster forward slightly and support the vacuum booster to access the brake booster pushrod retaining clip.

    13. Object Number: 1919795 Size: SH
  13. Release the retaining clip (1) and disengage the power vacuum brake booster input rod from the brake booster pushrod (2).
  14. Remove the vacuum power brake booster.

Installation Procedure

    Object Number: 1919795 Size: SH
  1. Install the vacuum power brake booster.
  2. Release the retaining clip (1) and engage the power vacuum brake booster input rod to the brake booster pushrod (2).
  3. Press the retaining clip into position on the brake booster pushrod

    4. Object Number: 1994008 Size: SH
  4. Position the power vacuum brake booster to the cowl.
  5. Press the vacuum power brake booster locking tab (1) while rotating the  J-22805-B Brake Booster Holder  (2) clockwise.

    6. Ensure the locking tab is fully engaged in the vacuum brake booster mounting plate.

  6. Remove the  J-22805-B Brake Booster Holder  from the vacuum power brake booster and discard the master cylinder nuts.

    7. Object Number: 1994005 Size: SH
  7. Install the master cylinder to the vacuum power brake booster.

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

  8. Install new master cylinder nuts (1) and tighten to  33 N·m (24 lb ft).

    9. Object Number: 1994002 Size: SH
  9. Connect the vacuum power brake booster check valve and hose assembly (1).
  10. Connect the vacuum power brake booster vacuum sensor electrical connector.
  11. Connect the brake fluid level switch electrical connector.
  12. Install the heater pipe assembly to the throttle body. Refer to Heater Pipes Replacement.
  13. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement for the 3.5L engine or Air Cleaner Outlet Duct Replacement for the 3.9L engine.
  14. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement for the 3.5L engine or Intake Manifold Cover Replacement for the 3.9L engine.