GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Vivant 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Power Vacuum Brake Booster Replacement

Removal Procedure

    Object Number: 1265691 Size: SH
  1. Remove the engine on right hand drive only. Refer to Engine Replacement for the 1.6L engine or Engine Replacement for the 2.0L (L34GMDAT) engine.
  2. Remove the master cylinder. Refer to Master Cylinder Replacement .
  3. Remove the vacuum hose from the brake booster.
  4. Remove the clevis pin and disconnect the pedal and brake booster push rod.
  5. Disconnect the retaining clip and the pin from the brake booster pushrod clevis.
  6. Remove the brake booster mounting nuts from studs protruding from dash panel and remove the brake booster.

    7. Object Number: 1265694 Size: SH
  7. Remove and discard the gasket.

    8. Object Number: 1265695 Size: SH
  8. Remove the pushrod clevis.

    9. Object Number: 1265696 Size: SH
  9. Remove the hex nut from the pushrod.

    10. Object Number: 1265697 Size: SH
  10. Remove the spring clip.
  11. Remove the rubber boot.

Installation Procedure

    Object Number: 1265699 Size: SH
  1. Install the rubber boot.
  2. Measure the distance from the booster to the center of the fork in the bore.

    3. Specification
    The distance from the booster to the center of the fork in the bore should be 162.4 mm (6.39 in). RHD 127.4 mm (5.02 in)

  3. Install new gasket.

    4. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1265696 Size: SH
  4. Install hex nut to pushrod.

    5. Tighten
    Tighten the hex nut to 18 N·m (13 lb ft).


    Object Number: 1265695 Size: SH

    Important: Apply grease around the hole of the pushrod clevis pin.

  5. Install the pushrod clevis.
  6. Install the brake booster mounting nuts to studs in dash panel.

    7. Tighten
    Tighten the mounting nuts to 25 N·m (18 lb ft).

  7. Install brake booster.
  8. Connect the retaining clip and pin to the brake booster pushrod clevis.
  9. Install the clevis pin.

    10. Object Number: 1265693 Size: SH
  10. Connect the pedal and brake booster push rod.
  11. Install the vacuum hose to the brake booster.
  12. Install the engine on right hand drive only. Refer to Engine Replacement for the 1.6L engine or Engine Replacement for the 2.0L (L34 GMDAT) engine.
  13. Install the master cylinder. Refer to Master Cylinder Replacement .
  14. Bleed the brake system.

    15. Object Number: 1265691 Size: SH
  15. Inspect the system for leaks.