GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2004 🢒 L300/LW300 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Power Vacuum Brake Booster Replacement

Removal Procedure

    Caution: Refer to Brake Fluid Irritant Caution in the Preface section.


    Object Number: 891661 Size: SH
  1. On vehicles equipped with ABS, the ABS controller must be removed. Refer to Electronic Brake Control Module Replacement in Antilock Brake System.
  2. Remove the brake pipes from the master cylinder.
  3. Disconnect the low brake fluid switch electrical connector.
  4. Remove the master cylinder-to-brake booster nuts.
  5. Remove the master cylinder from the vehicle.
  6. Disconnect the vacuum check valve and the hose from the booster.

    7. Object Number: 891756 Size: SH
  7. Remove the left lower instrument panel (I/P) closeout panel, hush panel.
  8. Remove the booster push rod retainer and push rod from the brake pedal.

    9. Object Number: 891726 Size: SH
  9. Remove the brake booster-to-brake booster bracket attachment bolts.

    10.         Important: The top bolt is accessed through the inside of the HVAC filter plenum.

    9.1. Open the HVAC filter access panel.
    9.2. Remove the rubber plug in the bottom of the cowling.
    9.3. Remove the top brake booster-to-brake booster bracket bolt.
  10. From under the hood, remove the booster.

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 891726 Size: SH
  1. Position the booster in the vehicle. Install the brake booster-to-brake booster bracket attachment bolts.

    2. Tighten
    Tighten the brake booster-to-brake booster bracket bolts to 20 N·m (15 lb ft).

  2. Install the rubber plug in the bottom of the cowling.
  3. Close and secure the HVAC access panel.

    4. Object Number: 891756 Size: SH
  4. Install the booster push rod onto brake pedal pushrod, pin with the retainer.
  5. Install the lower left I/P closeout panel, hush panel.
  6. Connect the vacuum hose and the check valve to the booster.

    7. Object Number: 891661 Size: SH
  7. Position the master cylinder onto the brake booster and install the fastening nuts.

    8. Tighten
    Tighten the master cylinder-to-brake booster nuts to 25 N·m (18 lb ft).

    Important: Do not bend the brake pipes.

  8. Position the brake pipes into the master cylinder and tighten the nuts.

    9. Tighten
    Tighten the brake pipe-to-master cylinder nuts to 16 N·m (12 lb ft).

  9. Connect low brake fluid electrical connector.
  10. On vehicles equipped with ABS, install the ABS Controller. Refer to Electronic Brake Control Module Replacement in Antilock Brake System.
  11. Bleed the brakes. Refer to Hydraulic Brake System Bleeding .