Power Booster Assembly Installation

WARNING: This page is about a different car, the 2006 Suzuki Verona. However, it is still accessible from the selected car via links, so may be relevant.

Check the pushrod and the pushrod clevis for damage and proper fit.
Install the new foam rubber and fiber packings, and install the new rubber boot on the booster shaft.

Fig 1: Removing/Installing Booster Rubber Boot
Courtesy of SUZUKI OF AMERICA CORP.
Install the spring clip.

Fig 2: Removing/Installing Booster Pushrod Spring Clip
Courtesy of SUZUKI OF AMERICA CORP.
Install the hex nut and the pushrod clevis.
Tighten:
- Tighten the booster pushrod hex nut to 18 N.m (13 lb-ft).
- Tighten the pushrod clevis to 18 N.m (13 lb-ft).
  
  Fig 3: Removing/Installing Booster Hex Nut And Pushrod Clevis
  Courtesy of SUZUKI OF AMERICA CORP.
Measure the distance from the booster to the center of the fork bin bore.
Specification

This measurement should be 141.7 mm (5.58 in.).

Fig 4: Identifying Distance From Booster To Center Of Fork Bin Bore
Courtesy of SUZUKI OF AMERICA CORP.
Install the new gasket.
Install the booster and the mounting nuts to the dash panel.
Tighten:

Tighten the booster-to-dash panel nuts to 22 N.m (16 lb-ft).

Fig 5: Removing/Installing Booster Gasket
Courtesy of SUZUKI OF AMERICA CORP.
Install the master cylinder onto the booster. Refer to Master Cylinder Assembly Installation .
Install the new vacuum hose to the booster. Refer to Vacuum Hose Installation .
Install the hose clamp on the vacuum hose.

Fig 6: Identifying Vacuum Hose Clip Connection And Brake Booster
Courtesy of SUZUKI OF AMERICA CORP.
Install the pushrod pin to the brake pedal bracket assembly and connect the clip and the spring.
Connect the brake stoplamp switch. Refer to Stoplamp Switch Installation .

Fig 7: Removing/Installing Pushrod Pin
Courtesy of SUZUKI OF AMERICA CORP.