GM Service Manual Online
For 1990-2009 cars only

Master Cylinder Replacement JD9


Object Number: 1707592  Size: SF

Callout

Component Name

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.

 

1

Brake Pipe Fitting (Qty: 2)

Notice: Refer to Fastener Notice in the Preface section.

Tip

    • Using a suitable tool, remove the brake fluid from the master cylinder reservoir.
    • Cap or plug the brake pipes to prevent brake fluid loss and the contamination of the brake system.

Tighten
25 N·m (18 lb ft)

2

Master Cylinder Nut (Qty: 2)

Tighten
33 N·m (24 lb ft)

3

Brake Master Cylinder

Tip

    • Disconnect/connect the brake fluid level sensor electrical connector.
    • Bleed the brake system. Refer to Hydraulic Brake System Bleeding .

Master Cylinder Replacement JH6


Object Number: 1707701  Size: SF

Callout

Component Name

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.

 

1

Brake Pipe Fitting (Qty: 2)

Notice: Refer to Fastener Notice in the Preface section.

Tip

    • Using a suitable tool, remove the brake fluid from the master cylinder reservoir.
    • Cap or plug the brake pipes to prevent brake fluid loss and contamination of the brake system.

Tighten
25 N·m (18 lb ft)

2

Brake Master Cylinder Nut (Qty: 2)

Tighten
33 N·m (24 lb ft)

3

Brake Master Cylinder

Tip

    • Disconnect/connect the brake fluid level sensor electrical connector.
    • Bleed the brake system. Refer to Hydraulic Brake System Bleeding .

Master Cylinder Replacement Two-mode Hybrid

Removal Procedure

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.

    Important: The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes.

  1. Turn the ignition to OFF, without pausing at ACCESSORY, and remove the ignition key.
  2. Important: During the pressure relief process, the fluid level in the master cylinder reservoir will rise. Do not remove the master cylinder reservoir cap during the pressure relief process.

  3. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete.
  4. Remove the brake fluid from the brake master cylinder reservoir and discard into an approved container.
  5. Disconnect the brake fluid level sensor electrical connector.

  6. Object Number: 1892190  Size: SH
  7. Disconnect the brake master cylinder reservoir return hose quick connect (1) and position the hose aside.
  8. Disconnect the brake master cylinder reservoir supply hose quick connect (2) and position the hose aside.

  9. Object Number: 1892200  Size: SH
  10. Disconnect the brake master cylinder primary brake pipe fitting (1).
  11. Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.


    Object Number: 1892202  Size: SH
  12. Disconnect the brake master cylinder left supply brake pipe fitting (1).
  13. Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.


    Object Number: 1892213  Size: SH
  14. Disconnect the brake master cylinder right supply brake pipe fitting (1).
  15. Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.


    Object Number: 1892216  Size: SH
  16. Disconnect the brake master cylinder right front brake pipe fitting (1).
  17. Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.


    Object Number: 1892220  Size: SH
  18. Disconnect the brake master cylinder left front brake pipe fitting (1).
  19. Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.


    Object Number: 1892240  Size: SH
  20. Remove the brake master cylinder nuts (1).
  21. Discard the brake master cylinder nuts.


    Object Number: 1892241  Size: SH
  22. Remove the brake master cylinder and the master cylinder seal (1).

Installation Procedure

  1. Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding.

  2. Object Number: 1892241  Size: SH
  3. Install the brake master cylinder seal (1) and the master cylinder to the adapter.
  4. Ensure the brake master cylinder seal is fully seated in the groove on the master cylinder housing.

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1892240  Size: SH
  5. Install 2 new brake master cylinder nuts (1).
  6. Tighten
    Tighten the nuts to 33 N·m (24 lb ft).


    Object Number: 1892220  Size: SH
  7. Connect the brake master cylinder left front brake pipe fitting (1).
  8. Tighten
    Tighten the fitting to 30 N·m (22 lb ft).


    Object Number: 1892216  Size: SH
  9. Connect the brake master cylinder right front brake pipe fitting (1).
  10. Tighten
    Tighten the fitting to 30 N·m (22 lb ft).


    Object Number: 1892213  Size: SH
  11. Connect the brake master cylinder right supply brake pipe fitting (1).
  12. Tighten
    Tighten the fitting to 30 N·m (22 lb ft).


    Object Number: 1892202  Size: SH
  13. Connect the brake master cylinder left supply brake pipe fitting (1).
  14. Tighten
    Tighten the fitting to 30 N·m (22 lb ft).


    Object Number: 1892200  Size: SH
  15. Connect the brake master cylinder primary brake pipe fitting (1).
  16. Tighten
    Tighten the fitting to 30 N·m (22 lb ft).


    Object Number: 1892190  Size: SH
  17. Connect the brake master cylinder reservoir return hose quick connect (1).
  18. Connect the brake master cylinder reservoir supply hose quick connect (2).
  19. Connect the brake fluid level sensor electrical connector.
  20. Fill the brake master cylinder reservoir. Refer to Master Cylinder Reservoir Filling.
  21. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding.