GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2000 🢒 Bonneville 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Power Vacuum Brake Booster Replacement

Removal Procedure
  1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical -- 3.8L.
  2. Remove the air inlet duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls -- 3.8L.
  3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls -- 3.8L.
  4. Remove the accelerator control cable bracket and position the cables out of the way. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls -- 3.8L.
  5. Disconnect the engine harness clip from the EGR heat shield and position out of the way.

    6. Object Number: 450528 Size: SH
  6. Disconnect the cruise control cable (1) from the cruise module (2).
  7. Disconnect the brake fluid level sensor wire connector.

    8. Object Number: 420706 Size: SH
  8. Remove the master cylinder attaching nuts.
  9. Remove the master cylinder from the booster. Carefully set the master cylinder aside.
  10. Remove the booster vacuum hose from the vacuum check valve.

    11. Object Number: 420708 Size: SH
  11. Remove the booster pushrod from the brake pedal.
  12. Remove the booster attaching nuts from the brake pedal assembly.

    13. Object Number: 106322 Size: SH
  13. Remove the booster from the vehicle.
  14. Remove the gasket.

Installation Procedure
  1. Install the gasket to booster.

    2. Object Number: 106322 Size: SH
  2. Install the booster to the vehicle.

    3. Object Number: 420708 Size: SH
  3. Install the booster pushrod to the brake pedal and secure with spacer and clip.

    4. 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.

  4. Install the booster attaching nuts onto the booster studs.

    5. Tighten
    Tighten the brake pedal to booster stud nuts to 23 N·m (17 lb ft).


    Object Number: 420706 Size: SH
  5. Install the master cylinder onto the vacuum brake booster
  6. Install the master cylinder attaching nuts.

    7. Tighten
    Tighten the nuts to 23 N·m (17 lb ft).

  7. Install the booster vacuum hose from the vacuum check valve.
  8. Connect the brake fluid level sensor wire connector.

    9. Object Number: 450528 Size: SH
  9. Install the cruise control cable (1) to the module (2).
  10. Install the accelerator control cable bracket. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls -- 3.8L.
  11. Connect the engine harness clips from the accelerator control bracket and the EGR shield.
  12. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement 1 in Engine Controls -- 3.8L.
  13. Install the air inlet duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls -- 3.8L.
  14. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical -- 3.8L.