GM Service Manual Online
For 1990-2009 cars only

Step

Action

Value(s)

Yes

No

1

Did you perform the Hydraulic Brake System Diagnostic Check?

--

Go to Step 2

Go to Hydraulic Brake Diagnostic System Check

2

Inspect the hydraulic brake system for leaks. Refer to Brake Fluid Leak .

Are there any leaks?

--

Go to Step 3

Go to Step 5

3

  1. Tighten the brake hose or pipe fittings. Refer to Fastener Tightening Specifications .
  2. Start the engine.
  3. Press the brake pedal several times.
  4. Turn OFF the engine.
  5. Inspect the hydraulic brake system for leaks.

Has the leak returned?

--

Go to Step 4

Go to Step 29

4

Replace the brake hose or the brake pipe as necessary. Refer to the appropriate procedure:

    •  Brake Pipe Replacement

Is the repair complete?

--

Go to Step 29

--

5

Inspect the disc brake pads and brake shoe linings for the following conditions:

    • Excessive wear
    • Uneven wear
    • Abuse
    • Glazing
    • Contaminated lining material
    • Incorrect lining material

Refer to Brake Pad Inspection in Disc Brakes or Brake Shoe Inspection in Drum Brakes.

Do any of the above conditions apply?

--

Go to Step 6

Go to Step 7

6

Replace the brake linings. Refer to the appropriate procedure:

    •  Front Disc Brake Pads Replacement in Disc Brakes
    •  Rear Disc Brake Pads Replacement in Disc Brakes
    •  Brake Shoe Replacement in Drum Brakes

Is the repair complete?

--

Go to Step 29

--

7

Inspect the following brake caliper assembly components for corrosion:

    • Mounting bolts
    • Sleeves
    • Steering knuckle
    • Brake caliper
    • Brake caliper piston

Refer to Brake Caliper Inspection in Disc Brakes.

Are any of the above components corroded or sticking?

--

Go to Step 8

Go to Step 9

8

Replace the corroded components. Refer to the appropriate procedure:

    •  Front Brake Caliper Overhaul in Disc Brakes
    •  Rear Brake Caliper Overhaul in Disc Brakes
    •  Front Brake Caliper Replacement in Disc Brakes
    •  Rear Brake Caliper Replacement in Disc Brakes

Is the repair complete?

--

Go to Step 29

--

9

Inspect the brake assembly for loose, missing or broken components. Refer to Brake Pad Inspection in Disc Brakes or Brake Shoe Inspection in Drum Brakes.

Are there loose, missing or broken brake assembly components?

--

Go to Step 10

Go to Step 11

10

Tighten or replace the components as necessary. Refer to the appropriate procedure:

    •  Front Disc Brake Pads Replacement in Disc Brakes
    •  Rear Disc Brake Pads Replacement in Disc Brakes
    •  Brake Shoe Replacement in Drum Brakes

Is the repair complete?

--

Go to Step 29

--

11

  1. Inspect the wheel cylinder for leakage.
  2. Inspect the wheel cylinder for binding.

Is the wheel cylinder leaking or binding?

--

Go to Step 12

Go to Step 13

12

Overhaul or replace the wheel cylinder. Refer to Wheel Cylinder Overhaul or Wheel Cylinder Replacement in Drum Brakes.

Is the repair complete?

--

Go to Step 29

--

13

  1. Inspect the brake pedal assembly for bent or misaligned components.
  2. Inspect the brake pedal for interference (binding) between the pedal and the booster input rod.

Is the brake pedal binding?

--

Go to Step 14

Go to Step 15

14

  1. Disassemble and realign or replace components as necessary.
  2. Replace the brake pedal. Refer to Brake Pedal Replacement .

Is the repair complete?

--

Go to Step 29

--

15

Inspect the brake pedal for interference with other components. Inspect the brake pedal area for the following conditions:

    • Loose or misaligned the trim panels
    • Loose components, wiring harnesses or aftermarket devices

Are there any loose or interfering components?

--

Go to Step 16

Go to Step 17

16

Realign or reposition components as necessary.

Is the repair complete?

--

Go to Step 29

--

17

    • Inspect for collapsed , dented, or bent brake pipes. Refer to Brake Fluid Leak .
    • Inspect the brake hoses for sharp kinks. Refer to Brake Fluid Leak .

Are the brake hoses or the brake pipes collapsed, bent, or kinked?

--

Go to Step 18

Go to Step 19

18

Reroute or replace the brake hoses or the brake pipes as necessary. Refer to the appropriate procedure:

    •  Brake Pipe Replacement

Is the repair complete?

--

Go to Step 29

--

19

  1. Remove the master cylinder reservoir cap.
  2. Rapidly apply the brake pedal 3 cm (1 in), observing the brake fluid in the reservoir.

Does the fluid surface in the reservoir show movement, or spouting?

--

Go to Step 20

Go to Step 21

20

  1. Install the master cylinder reservoir cap.
  2. Loosen the master cylinder mounting nuts 13 mm (½ in).
  3. Separate the master cylinder from the vacuum brake booster.
  4. Apply the brake pedal 3 cm (1 in).

Does the booster output rod move?

--

Go to Step 23

Go to Step 22

21

Replace the master cylinder. Refer to Master Cylinder Replacement .

Is the repair complete?

--

Go to Step 29

--

22

Replace the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement .

Is the repair complete?

--

Go to Step 29

--

23

  1. Remove the master cylinder reservoir cap.
  2. Inspect the brake fluid for contamination. Refer to Brake Fluid and Brake Fluid Handling .

Is the brake fluid contaminated?

--

Go to Step 24

Go to Step 25

24

  1. Replace all of the rubber brake system components. Refer to the following procedures:
  2. •  Wheel Cylinder Overhaul in Drum Brakes
    •  Front Brake Caliper Overhaul in Disc Brakes
    •  Rear Brake Caliper Overhaul in Disc Brakes
  3. Flush the hydraulic brake system. Refer to Hydraulic Brake System Flushing .

Is the repair complete?

--

Go to Step 29

--

25

Inspect the master cylinder outlet ports for restricted passages. Refer to Hydraulic Brake System Bleeding .

Are the outlet ports restricted?

--

Go to Step 26

Go to Step 27

26

  1. Overhaul the master cylinder. Refer to Master Cylinder Overhaul .
  2. Flush the hydraulic brake system. Refer to Hydraulic Brake System Flushing .

Is the repair complete?

--

Go to Step 29

--

27

Inspect the brake pipes and the brake hoses for restricted passages. Refer to Hydraulic Brake System Flushing .

Inspect for the following conditions:

    • Low fluid or no fluid output
    • Spurting of fluid while pressing the brake pedal
    • Particles suspended in the fluid

Do any of the above conditions apply?

--

Go to Step 28

Go to Step 29

28

  1. Determine the area of the restriction. This will involve the disassembly of individual brake lines and checking for low fluid output.
  2. Flush the individual brake line or the brake hose.
  3. If the restriction cannot be removed, replace the brake hose or the brake pipe as necessary. Refer to the appropriate procedure:
  4. Flush the hydraulic brake system. Refer to Hydraulic Brake System Flushing .

Is the repair complete?

--

Go to Step 29

--

29

Verify the proper brake system operation.

Does the brake system operate properly?

--

System OK

Go to Hydraulic Brake Diagnostic System Check