GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2002 🢒 Savana 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Power Vacuum Brake Booster Replacement

Removal Procedure
  1. Remove the brake master cylinder. Refer to Master Cylinder Replacement .

    2. Object Number: 161494 Size: SH
  2. Remove the vacuum hose from the check valve.
  3. Remove the check valve from the power brake booster.
  4. Remove the pushrod retainer, the pushrod, and the stoplamp switch for the power brake booster from the brake pedal. Refer to Stop Lamp Switch Replacement .

    5. Object Number: 161490 Size: SH
  5. Remove the retaining nuts for the power brake booster from the brake pedal bracket.
  6. Remove the power brake booster from the front engine cowl.
  7. Remove the gasket between the power brake booster and the front engine cowl.

Installation Procedure

    Object Number: 161490 Size: SH
  1. Install the gasket between the power brake booster and the front engine cowl.
  2. Install the power brake booster to the front engine cowl.

    3. 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 retaining nuts for the power brake booster to the brake pedal bracket.

    4. Tighten
    Tighten the power brake booster retaining nuts to 36 N·m (27 lb ft).

    Important: Tighten the power brake booster retaining nuts to the cowl by using the following cross pattern method sequence. Make sure to tighten the nuts evenly before tightening to specifications.

    1. Right lower retaining nut
    2. Left upper retaining nut
    3. Left lower retaining nut
    4. Right upper retaining nut

  4. Recheck the torque after all nuts have been tightened.
  5. Install the stoplamp switch, the pushrod, and the pushrod retainer to the brake pedal. Refer to Stop Lamp Switch Replacement .

    6. Object Number: 161494 Size: SH
  6. Install the check valve to the power brake booster.
  7. Install the vacuum hose to the check valve.
  8. Install the brake master cylinder to the power brake booster. Refer to Master Cylinder Replacement .
  9. Bleed the brake system. Refer to Hydraulic Brake System Bleeding .