OEM 2004 Chevrolet Malibu Brake Booster

2004 Chevrolet Malibu Parts Questions & Experts Answers

• Q: How to replace the Vacuum Brake Booster (W/O ABS) on 2004 Chevrolet Malibu?

  A: Starting the vacuum Brake Booster (W/O ABS) replacement requires a vehicle lift and turning off the ignition. Start by first removing the left front wheel and tire assembly followed by removing the 2 nuts holding the proportioning valve bracket to the left front wheelhouse. To reduce vacuum pressure in the vacuum Brake Booster detach the vacuum check valve from the vacuum Brake Booster grommet while leaving it connected to the vacuum brake hose. Dikkat : place bleeder valve caps onto the 4 brake pipes leading to the proportioning valve to stop brake fluid loss and protect the system from contaminants. Separate the master cylinder nuts from the vacuum Brake Booster and remove the proportioning valve bracket assembly alongside the Brake Master Cylinder from the vehicle. Start by taking off the closeout panel and electrical connector of the brake apply sensor before unfastening the 2 mounting nuts for the Brake Pedal assembly to cowl framework. Disconnect the Brake Pedal pushrod retaining clip , the wave washers and Brake Booster pushrod from the Brake Pedal pin before gently tilting the vacuum Brake Booster to work the pushrod off the pin while carefully avoiding excessive side pressure. Move the booster unit out of the vehicle. Install the booster into the vehicle by gently tilting it while lining up the booster pushrod with the Brake Pedal pin before final assembly. Quality installation requires users to reattach the Brake Pedal pushrod retaining clip alongside wave washers as they connect to the Brake Pedal pin and keep the 2 Brake Pedal assembly to cowl mounting nuts at 15 nm (11 ft. Lbs.) torque. Reinstall the brake apply sensor electrical connector before installing the closeout panel. Position the Brake Master Cylinder gasket properly on its outer barrel before assembling the proportioning valve bracket assembly with the Brake Master Cylinder while inspecting the gasket for cuts or tears. Secure master cylinder nuts to the vacuum Brake Booster by tightening them to 25 nm (18 ft. Lbs.). Reposition the vehicle before you fasten and adjust the two nuts connecting the proportioning valve bracket assembly to left wheelhouse to 10 nm (86 inch lbs. Torque). Lower the vehicle after reinstallation of the left front tire assembly before opening all 4 brake pipes and connecting them to the proportioning valve with tightening of each pipe to 20 nm (15 ft. Lbs.). To complete this process connect the vacuum Brake Booster check valve to the vacuum Brake Booster grommet then perform hydraulic brake system bleaching followed by Brake Pedal position sensor calibration.