Installation Procedure

WARNING: This page is about a different car, the 2008 Suzuki Swift +, 2008 Pontiac Wave, and 2008 Chevrolet Aveo. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Inspecting Pushrod and Adjustment Sleeve For Damage and Proper Fit

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NOTE: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .

Inspect the pushrod and the adjustment sleeve for damage and proper fit.

Fig 2: View of Adjustment Sleeve, Hex Nut, and Pushrod

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NOTE: Refer to Fastener Notice .

Install the hex nut and the adjustment sleeve on the booster.
Tighten: Tighten the booster pushrod hex nut and the adjustment sleeve to 16 N.m (12 lb ft).

Fig 3: View of Stop Lamp Switch, Retaining Ring, Pin, And Pushrod/Brake Pedal Connection Spring

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IMPORTANT: This measurement (a) should be 278.5 mm (10 in).

Insert the pushrod in the adjustment sleeve and mount the retainer.
Measure the distance from the booster to the center of the fork bin bore.

Fig 4: View of Rubber Boot and Retainer

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Install the rubber boot on the booster.

Fig 5: View of Booster and Bracket Nuts

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Install the brackets to the booster.
Tighten: Tighten the booster-to-support bracket nuts to 12 N.m (9 lb ft).

Fig 6: View of Clutch Hose Connection Clip and Master Cylinder (Manual Transaxle)

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Install the booster and the bracket assembly to the dash panel.
Tighten: Tighten the booster and support bracket-to-dash panel nuts to 24 N.m (18 lb ft).

Fig 7: View of Booster and Bracket Nuts

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Connect the master cylinder to the booster and install a new booster housing seal.
Tighten: Tighten the master cylinder attaching nuts to 24 N.m (18 lb ft).

Fig 8: View of Clip On Vacuum Hose Connection To Booster (DOCH Engine)

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Install the new vacuum hose to the booster, DOHC engine connection shown. Refer to Vacuum Brake Booster Check Valve and/or Hose Replacement .
Install new hose clamps on the vacuum hose.
Install the pushrod pin to the brake pedal bracket assembly and connect the clip and the spring. Refer to Brake Pedal Assembly Replacement .
Install the brake lamp switch.