Installation Procedure

WARNING: This page is about a different car, the 2007 Suzuki XL7. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Brake Booster Push Rod-To-Brake Pedal Retaining Clip And Foam Washer

Courtesy of SUZUKI OF AMERICA CORP.

Install the foam insulator the vacuum brake booster.
Install the brake booster to the vehicle.
Install, but do not tighten, the booster mounting nuts.
Lightly lubricate the booster push rod pivot pin on the brake pedal with silicone lubricant.
Install the booster push rod to the pivot pin on the brake pedal.
Install the foam washer to the pivot pin.
Install the brake booster push rod retaining clip.

Fig 2: Identifying Brake Booster Mounting Nuts
Courtesy of SUZUKI OF AMERICA CORP.
Fully seat the brake booster to the front of dash and the brake pedal assembly.
CAUTION:
Refer to FASTENER NOTICE .
Tighten the vacuum brake booster mounting nuts.
Tightening torque

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

Fig 3: Identifying Brake Pressure Modulator Valve Bracket And Nuts
Courtesy of SUZUKI OF AMERICA CORP.
Install the brake pressure modulator valve bracket. Refer to BRAKE PRESSURE MODULATOR VALVE BRACKET REPLACEMENT .
Install the brake pressure modulator valve assembly. Refer to BRAKE PRESSURE MODULATOR VALVE REPLACEMENT .

Fig 4: Identifying Vacuum Hose Check Valve
Courtesy of SUZUKI OF AMERICA CORP.
Install the vacuum booster check valve and hose assembly to the booster.
Reposition and install the master cylinder to the booster. Refer to INSTALLATION PROCEDURE .

Fig 5: Installing Coolant Surge Hose & Clamp To Surge Tank
Courtesy of SUZUKI OF AMERICA CORP.
Install the coolant surge hose and clamp to the surge tank.
Install the underhood electrical center. Refer to UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT .
If necessary, bleed the brake system. Refer to HYDRAULIC BRAKE SYSTEM BLEEDING (PRESSURE) and HYDRAULIC BRAKE SYSTEM BLEEDING (MANUAL) .