GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 SL1/SC1 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Power Vacuum Brake Booster Replacement

Removal Procedure

    Object Number: 863522 Size: SH

    Important: The vacuum booster and pushpin are a matched set. Boosters are measured during manufacturing and a pushpin of the correct length is selected and fitted to the booster. Boosters and pushpins are not interchangeable and must always be installed as a set.

  1. Disconnect the negative battery cable.
  2. Remove the air cleaner from the vehicle.
  3. Disconnect the positive battery cable from the terminal.
  4. Remove the battery hold-down retaining nut and screw, and lift off the battery hold-down retainer.
  5. Lift the battery off the vehicle. Place the battery in a safe location.

    6. Object Number: 866694 Size: SH

    Important: On manual transaxle equipped vehicles, the clutch reservoir and bracket need to be removed and put aside.

  6. Remove the master cylinder-to-brake booster nuts.

    7. Object Number: 866698 Size: SH

    Notice: Do not bend brake pipes.

  7. Move the master cylinder control assembly away from the booster, far enough that the brake booster can be removed.
  8. Disconnect the vacuum check valve and hose from the booster.
  9. Remove the booster push rod retainer and washer.
  10. Remove the four nuts attaching the vacuum booster to the vehicle interior.
  11. From under the hood, remove the booster. Tilt the booster to disengage the push rod from the brake pedal pin.

Installation Procedure

    Object Number: 867265 Size: SH
  1. Position the booster in the vehicle. Do not install the fasteners at this time.
  2. Lubricate the brake pedal push rod pin.
  3. Install the booster push rod onto the brake pedal pushrod pin with the retainer and washer.
  4. Install the four booster-to-body fasteners.

    5. Tighten
    Tighten the fastener to 27 N·m (20 lb ft).

  5. Connect the vacuum hose and check valve-to-booster.

    6. Notice: Do not bend brake pipes.

    Important: On manual transaxle equipped vehicles, install the clutch reservoir bracket prior to installing fasteners.

  6. Position the master cylinder onto the brake booster studs and install the fasteners.

    7. Tighten
    Tighten the fasteners to 27 N·m (20 lb ft).


    Object Number: 863522 Size: SH

    Important: Make sure the battery tray is clean. Make sure that the battery cable ends are clean and free of corrosion. Clean with a wire brush. Make sure that the battery is in good physical condition (e.g., no cracks, or obvious damage) and that the terminals are clean.

  7. Install the battery carefully in the battery tray; make sure that the terminals do not short against any metal during the installation.
  8. Install the battery hold-down retainer, locking the battery into the tray.
  9. Install and tighten the hold-down retainer nut and screw.

    10. Tighten
    Tighten the nut to 9 N·m (80 lb in).

  10. Install the positive battery cable first.

    11. Tighten
    Tighten the positive battery cable to 17 N·m (13 lb ft).

  11. Install the negative battery cable last.

    12. Tighten
    Tighten the negative battery cable to 17 N·m (13 lb ft).

  12. Install the air cleaner assembly in the vehicle.
  13. Check and adjust the stop lamp switch.