GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1999 🢒 Malibu 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Power Vacuum Brake Booster Replacement

Removal Procedure

    Object Number: 385197 Size: SH
  1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement -2.4L, Air Cleaner Assembly Replacement -3.1L or Air Cleaner Assembly Replacement -3.1L (LG8) in Engine Controls.
  2. Disconnect the underhood junction block from the bracket. Refer to Underhood Fuse Block Replacement in Engine Electrical.
  3. Remove the underhood junction block bracket.
  4. Remove the master cylinder (2) from the booster (1).

    5. Do not lose or dislodge the insulator between the booster and the front of the dash.


    Object Number: 385226 Size: SH
  5. Disconnect the vacuum hose from the vacuum check valve (1).

    6. Object Number: 385267 Size: SH
  6. Remove the left sound insulator.
  7. Remove the booster attaching nuts (2).

    8. Object Number: 385262 Size: SH
  8. Remove the booster pushrod (1) from the brake pedal (2).

    9. Tilt the entire vacuum booster slightly in order to work the booster pushrod off the pedal clevis pin. Do not put undue side pressure on the pushrod.

  9. Remove the booster from the vehicle.

Installation Procedure

    Object Number: 385262 Size: SH
  1. Install the booster to the vehicle.
  2. Install the booster pushrod (1) to the brake pedal (2).

    3. Tilt the entire vacuum booster slightly in order to work the booster pushrod onto the pedal clevis pin without putting undue side pressure on the pushrod. Use the left hand in order to align the pushrod with the pedal and push together.


    Object Number: 385267 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 booster attaching nuts (2).

    4. Tighten
    Tighten the booster to brake pedal attaching nuts to 27 N·m (20 lb ft).

  4. Install the left sound insulator.

    5. Object Number: 385226 Size: SH
  5. Connect the vacuum hose to the vacuum check valve (1).

    6. Object Number: 385197 Size: SH
  6. Install the master cylinder (2) to the booster (1).
  7. Install the master cylinder attaching nuts.

    8. Tighten
    Tighten the master cylinder to booster attaching nuts to 27 N·m (20 lb ft).

  8. Install the underhood junction block bracket.
  9. Install the underhood junction block. Refer to Underhood Fuse Block Replacement in Engine Electrical.
  10. Install the cleaner assembly. Refer to Air Cleaner Assembly Replacement -2.4L, Air Cleaner Assembly Replacement -3.1L or Air Cleaner Assembly Replacement -3.1L (LG8) in Engine Controls.