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

Removal Procedure

    Object Number: 179548 Size: SH
  1. Remove the air cleaner assembly (2). Refer to Air Cleaner Assembly Replacement in Engine Controls 2.4L or Air Cleaner Assembly Replacement in Engine Controls 3.4L.
  2. Move the underhood fuse block forward.
  3. Remove the underhood fuse block bracket.

    4. Object Number: 385197 Size: SH
  4. Remove the master cylinder (2) attaching nuts from brake booster (1).
  5. Remove the master cylinder from booster.

    6. Object Number: 385226 Size: SH
  6. Remove the vacuum hose from vacuum check valve (1).
  7. Remove the left instrument panel insulator.

    8. Object Number: 385262 Size: SH
  8. Disconnect the booster pushrod (1) from the brake pedal (2).

    9. Object Number: 385267 Size: SH
  9. Remove the booster attaching nuts (2).
  10. Remove the booster from the vehicle.
  11. Inspect the booster sound insulator for damage. Replace if necessary.

Installation Procedure
  1. Install the booster to the vehicle.

    2. Object Number: 385267 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.

  2. Install the booster attaching nuts.

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


    Object Number: 385262 Size: SH
  3. Connect the booster pushrod (1) to the brake pedal (2).
  4. Install the left instrument panel insulator.

    5. Object Number: 385226 Size: SH
  5. Install the vacuum hose to the vacuum check valve (1).

    6. Object Number: 385197 Size: SH
  6. Install the master cylinder to the booster.
  7. Install the master cylinder (2) mounting nuts from brake booster (1).

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

  8. Install the underhood fuse block bracket.

    9. Object Number: 179548 Size: SH
  9. Install the underhood fuse block.
  10. Install the air cleaner assembly (2). Refer to Air Cleaner Assembly Replacement in Engine Controls 2.4L or Air Cleaner Assembly Replacement in Engine Controls 3.4L.