GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Optra - Mexico 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Power Vacuum Brake Booster Replacement

Removal Procedure

    Object Number: 1289933 Size: SH
  1. Remove the master cylinder. Refer to Master Cylinder Replacement .

    2. Object Number: 1289949 Size: SH
  2. Remove the shaft and the rubber O-ring.

    3. Object Number: 1289948 Size: SH
  3. Spread the clip on the vacuum hose connection to the brake booster and move the clip away from the booster.
  4. Remove the vacuum hose from the booster.
  5. Disconnect the stop lamp switch. Refer to Stop Lamp Switch Replacement .
  6. Remove the brake pedal spring.
  7. Remove the clip and the pushrod pin from the pedal bracket assembly.

    8. Object Number: 1289950 Size: SH
  8. Remove the booster mounting nuts from the studs protruding from the dash panel and remove the booster.
  9. Remove the rubber boot.

    10. Object Number: 1289951 Size: SH
  10. Holding the hex nut, twist off the pushrod clevis.
  11. Remove the hex nut from the pushrod.

Installation Procedure

    Object Number: 1289952 Size: SH
  1. Inspect the pushrod and the pushrod clevis for damage and proper fit.
  2. Install the hex nut and the pushrod clevis on the booster shaft.

    3. Object Number: 1289953 Size: SH
  3. Measure the distance from the booster to the center of the fork pin bore.

    4. Specification
    The distance from the booster to the center of the fork pin bore should be 120 mm (4.7 in).

  4. Install the rubber boot to the booster.

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

  5. Tighten the booster hex nut and the pushrod clevis.

    6. Tighten
    Tighten the booster hex nut and the pushrod clevis to 18 N·m (13 lb ft).


    Object Number: 1289954 Size: SH
  6. Install the booster and the mounting nuts to the dash panel.

    7. Tighten
    Tighten the booster-to-dash panel nuts to 22 N·m (16 lb ft).


    Object Number: 1289949 Size: SH
  7. Attach the shaft and the rubber O-ring.
  8. Connect the master cylinder to the booster. Refer to Master Cylinder Replacement .
  9. Connect the brake line fittings to the hydraulic modulator, if applicable.

    10. Tighten

        • Tighten the brake line fittings to 16 N·m (12 lb ft).
        • Tighten the master cylinder attaching nuts to 24 N·m (18 lb ft).

    Object Number: 1289948 Size: SH
  10. Install the vacuum hose and the clip to the booster.
  11. Install the hose clamps on the vacuum hose, and snap the vacuum hose in the revolving clip.
  12. Ensure the vacuum hose connections are tight at each end.
  13. Install the pushrod pin to the brake pedal bracket assembly and connect the clip and the spring.
  14. Install the stop lamp switch. Refer to Stop Lamp Switch Replacement .