Contents: Removal ↧ Installation ↧
Removal
1. Disconnect the electrical connector from the tank.
2. For vehicles with a manual transmission, disconnect the clamp connecting the clutch hose to the brake master cylinder.
3. Plug the hose and master cylinder holes so that no fluid can leak out.
4. Remove the master cylinder mounting nuts.
5. Press the master cylinder lightly and pull it out from the guide. Do not disconnect the brake pipes.
6. Remove the amplifier housing seal,
7. Remove the clamp connecting the vacuum hose to the booster (the figure shows the DOHC engine connection).
8. Disconnect the brake lamp switch.
9. Remove the brake pedal spring.
10. Disconnect the clamp and stem stud from the pedal bracket assembly.
11. Remove the nuts securing the amplifier and bracket to the rear panel of the engine compartment.
12. Remove the amplifier and bracket.
13. Remove the nuts securing the amplifier to the bracket, and then the amplifier.
14. Remove the rubber boot and retainer.
15. Remove the rod.
16. Remove the adjustment tube from the rod.
17. Remove the hex nut.
Installation
1. Check the stem and adjustment tube for damage and proper fit.
2. Tighten the booster rod hex nut and adjusting tube to 18 Nm.
3. Install the rod into the adjustment tube and then the retainer.
4. Measure the distance from the amplifier to the center of the fork holes.
Note: This distance should be 278.5 mm.
5. Install the rubber boot onto the amplifier.
6. Install the brackets on the amplifier and tighten the mounting nuts to a torque of 22 Nm.
7. Install the amplifier and bracket assembly to the rear panel of the engine compartment and tighten the mounting nuts to a torque of 24 Nm.
8. Connect the master cylinder to the booster and tighten the mounting nuts to a torque of 24 Nm.
9. Attach the new vacuum hose to the booster (the figure shows the DOHC engine connection)
10. Install new clamps on the vacuum hose.
11. Install the piston rod stud to the brake pedal bracket assembly and install the clamp and spring.
12. Install the lamp switch.
(The article is reprinted from the website: CHEVYMAN.ru)