Removal and Installation

REMOVAL
1. Disconnect battery ground cable.
2. Remove master cylinder as outlined under MASTER CYLINDER.
3. Disconnect vacuum hose from brake booster. Then remove wiper motor.
4. Remove pedal spring, clip and clevis pin.
5. Remove alternator, PCV pipe and hose. Then disconnect No. 3 PCV hose from cylinder head cover.
6. Remove ISC valve. Then disconnect No. 3 water by-pass hose from throttle body.
7. Remove EGR pipe and cold start injector tube.
8. Remove manifold stay. Then remove air intake chamber and move it forward.
9. Remove booster nuts. Remove clevis pin of operating rod, then remove booster and gasket.

INSTALLATION
1. Adjust length of booster pushrod as follows:
a. Install gasket on master cylinder.
b. Install brake booster pushrod gauge tool No. 09737-00010, or equivalent on gasket.
c. Lower pin until its tip slightly touches the piston.
d. Turn gauge tool upside down and set it on booster.
e. Measure clearance between booster pushrod and pin head of gauge tool.
f. Adjust booster pushrod length until the pushrod slightly touches the pin head.
2. Install booster and gasket.
3. Install clevis to operating rod.
4. Install clevis pin into clevis and brake pedal then install clip to clevis pin.
5. Install air intake chamber and manifold stay. Torque to 13 ft.lbs.
6. Install EGR pipe and cold start injector tube. Torque to 13 ft.lbs.
7. Connect No. 3 water by-pass hose.
8. Install ISC valve.
9. Connect No. 3 PCV hose to cylinder head. Install PCV pipe with hose.
10. Install alternator, wiper motor, pedal return spring and master cylinder.
11. Connect hose to booster. Then fill reservoir with fluid and bleed system.
12. Check for leaks. Check and adjust brake pedal. Perform operational check.