GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Optra - Mexico 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Master Cylinder Overhaul

Disassembly Procedure

    Object Number: 1289942 Size: SH
  1. Remove the master cylinder. Refer to Master Cylinder Replacement .
  2. Remove the brake fluid reservoir. Refer to Master Cylinder Reservoir Replacement .
  3. Remove the seal ring from the cylinder bore.

    4. Important: When removing the retaining ring, avoid damaging the piston or the cylinder wall.

    Important: A welding rod or its equivalent can be used in a compensating port to keep the piston depressed.

  4. Remove and discard the retaining ring from the cylinder body using a suitable screwdriver. The non-antilock brake system (ABS) master cylinder body is shown.

    5. Object Number: 1289944 Size: SH
  5. Remove the primary piston. The ABS master cylinder body is shown.
  6. Carefully remove the secondary piston assembly, including the springs, from the master cylinder bore.

Assembly Procedure

    Object Number: 1289945 Size: SH

    Important: Do not use abrasives in the master cylinder bore.

    Important: Rubber parts and retaining rings must be discarded and replaced with new parts.

  1. Clean all parts with denatured alcohol or clean brake fluid. Dry the parts with compressed air.
  2. Inspect the master cylinder bore for scoring or corrosion. If scoring or corrosion is evident, replace the master cylinder body.
  3. Lubricate the master cylinder bore with clean brake fluid. The non-ABS master cylinder is shown.
  4. Carefully insert the secondary piston assembly bore until the secondary piston contacts the base of the cylinder body. Use a wood or a plastic drift, if necessary.
  5. Insert the primary piston.

    6. Object Number: 1289942 Size: SH
  6. Press the pistons into the cylinder bore using a wooden or a plastic drift.

    7. Important: Use care when installing the new retaining ring into the cylinder bore.

  7. Insert the new retaining ring into the groove in the cylinder bore. Remove the welding rod. The non-ABS cylinder body is shown.
  8. Move the pistons backward and forward after installation to check for free movement.
  9. Lubricate the seal ring and insert the seal into the cylinder bore. The open side must face outward until the seal rests on the piston.
  10. Install the brake fluid reservoir to the master cylinder. Refer to Master Cylinder Reservoir Replacement .
  11. Install the master cylinder assembly. Refer to Master Cylinder Replacement .
  12. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  13. Bleed the braking system. Refer to Hydraulic Brake System Bleeding .
  14. Lower the vehicle.