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

Removal Procedure

    Object Number: 171234 Size: SH
  1. Remove the air cleaner assembly. Refer to one of the following in Engine Controls:
    2. •  Air Cleaner Assembly Replacement   2.2 L (L61)
    •  Air Cleaner Assembly Replacement  2.2 L (LN2)
    •  Air Cleaner Assembly Replacement   2.4 L 
  2. Remove the master cylinder mounting nuts (10).
  3. Remove the master cylinder (11) from the booster (9).
  4. Move the master cylinder and the EBCM/BPMV forward just enough in order to clear the studs on the vacuum booster. This flexes the brake pipes slightly. Do not bend or distort the brake pipes.
  5. Remove the vacuum hose from the vacuum check valve.
  6. Remove the booster retaining nuts (7).

    7. Object Number: 188058 Size: SH
  7. Remove the left lower instrument panel.

    8. Remove the booster pushrod (2) from the brake pedal.

    Tilt the entire vacuum booster slightly in order to work the booster pushrod off the pedal clevis pin without putting undue pressure on the pushrod.

  8. Remove the booster from the vehicle.

Installation Procedure

    Object Number: 188058 Size: SH
  1. Install the booster onto the vehicle.
  2. Install the booster pushrod (2) to the brake pedal.

    3. Tilt the entire vacuum booster slightly in order to work the booster pushrod onto the pedal clevis pin without putting undue pressure on the pushrod.


    Object Number: 171234 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 brake booster to brake pedal retaining nuts (7).

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

  4. Install the left lower instrument panel.
  5. Install the booster vacuum hose to the vacuum check valve.
  6. Install the master cylinder (11) and the EBCM/BPMV to the booster (9).
  7. Install the master cylinder retaining nuts (10).

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

  8. Install the air cleaner assembly. Refer to one of the following in Engine Controls:
    9. •  Air Cleaner Assembly Replacement  2.2 L (L61)
    •  Air Cleaner Assembly Replacement  2.2 L (LN2)
    •  Air Cleaner Assembly Replacement   2.4 L