Master Cylinder Reservoir Replacement 1.6L Non-ABS

Caution: Brake fluid may irritate eyes and skin. In case of contact, take the following actions:

Notice: Brake fluid will damage electrical connections and painted surfaces. Use shop cloths, suitable containers, and fender covers to prevent brake fluid from contacting these areas. Always re-seal and wipe off brake fluid containers to prevent spills.

1. Disconnect the reservoir fluid level connector (2).
2. Clean the outside of the reservoir.



3. Remove the reservoir cap (1).
4. Remove the reservoir diaphragm (2).
5. Remove the fluid with a syringe.
6. Remove the reservoir connector screw (6).
7. Remove the reservoir (3).
8. Remove the grommets (4).

Caution: Use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid from a clean, sealed container. Do not use fluid from an open container that may be contaminated with water. Improper or contaminated fluid could result in damage to components, or loss of braking, with possible injury.

Notice: When filling the master cylinder, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid. Do not use a container which has been used for petroleum based fluids, or a container which is wet with water. Petroleum based fluids will cause swelling and distortion of rubber parts in the hydraulic brake system, and water will mix with brake fluid, lowering the boiling point. Keep all fluid containers capped to prevent contamination.

1. Lubricate new grommets (4) with Delco Supreme 11 brake fluid, GM P/N 12377967, or equivalent DOT-3 brake fluid. Press-fit the grommets to the master cylinder (5), and seat the grommets in place.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the reservoir (3). Secure the reservoir with the connector screw (6).

Tighten
Tighten the connector screw to 1.25 N·m (13.3 lb in).

3. Install the reservoir diaphragm (2).
4. Fill the reservoir. Refer to Master Cylinder Reservoir Filling .
5. Install the reservoir cap (1).
6. Inspect for fluid leakage.



7. Connect the reservoir fluid level connector (2).

Master Cylinder Reservoir Replacement 1.6L ABS/2.0L ABS/2.0L Non-ABS

Caution: Brake fluid may irritate eyes and skin. In case of contact, take the following actions:

Notice: Brake fluid will damage electrical connections and painted surfaces. Use shop cloths, suitable containers, and fender covers to prevent brake fluid from contacting these areas. Always re-seal and wipe off brake fluid containers to prevent spills.

1. Disconnect the reservoir fluid level connector (2).
2. Clean the outside of the reservoir.



3. Remove the reservoir cap (1).
4. Remove the reservoir diaphragm.
5. Remove the fluid with a syringe.
6. Remove the reservoir pin (5) using a drift.
7. Remove the reservoir (2).
8. Remove the reservoir grommets (3).

Caution: Use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid from a clean, sealed container. Do not use fluid from an open container that may be contaminated with water. Improper or contaminated fluid could result in damage to components, or loss of braking, with possible injury.

Notice: When filling the master cylinder, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid. Do not use a container which has been used for petroleum based fluids, or a container which is wet with water. Petroleum based fluids will cause swelling and distortion of rubber parts in the hydraulic brake system, and water will mix with brake fluid, lowering the boiling point. Keep all fluid containers capped to prevent contamination.

1. Lubricate new grommets (3) with Delco Supreme 11 brake fluid, GM P/N 12377967, or equivalent DOT-3 brake fluid. Press-fit the grommets to the master cylinder (4), and seat the grommets in place.

Important: Insert the reservoir pin until both of its ends at the right and the left of the reservoir become the same length.

2. Install the reservoir. Secure with the reservoir pin (5).
3. Install the reservoir diaphragm.
4. Fill the reservoir. Refer to Master Cylinder Reservoir Filling .
5. Install the reservoir cap (1).
6. Inspect for fluid leakage.



7. Connect the reservoir fluid level connector (2).