GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2009 🢒 Astra 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Master Cylinder Reservoir Replacement

Removal Procedure

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

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

  1. Remove the cover of the brake fluid reservoir.
  2. Siphon out as much brake fluid as possible with a siphon bottle.

    3. Object Number: 1941356 Size: SH
  3. Disconnect the wiring harness from the reservoir.
  4. Disconnect the wiring harness plug from the brake fluid level sensor (1).

    5. Object Number: 1941359 Size: SH

    Note: Collect the brake fluid and seal the apertures.

  5. Remove the brake fluid reservoir from the brake master cylinder.
    6. • Remove the bolt (1).
    • Remove the brake fluid reservoir carefully from the brake master cylinder.

    Object Number: 1941346 Size: SH

    Note: Collect the brake fluid and seal the apertures.

  6. For vehicles with manual transmission, remove the supply line for the clutch master cylinder from the brake fluid reservoir.
  7. Remove the brake fluid level sensor.

Installation Procedure

    Object Number: 1937675 Size: SH

    Note: Do not use mineral oils or greases when inserting seals (1) or when installing feed line for clutch master cylinder to brake fluid reservoir. If necessary, brake cylinder paste should be used.

  1. Replace seals (1) on the brake master cylinder.
  2. Install the brake fluid level sensor.
  3. For vehicles with manual transmission, install the supply line for the clutch master cylinder to the brake fluid reservoir.

    4. Caution: Refer to Fastener Caution in the Preface section.

    Note: Ensure the brake fluid reservoir is seated perfectly.

  4. Install the brake fluid reservoir to the brake master cylinder.
    5. • Install the brake fluid reservoir to the brake master cylinder.
    • Install the bolt.

    Tighten
    Tighten the brake fluid reservoir bolt to 6 N·m (53 lb in).

  5. Connect the wiring harness plug to the brake fluid level sensor.
  6. Connect the wiring harness on at the brake fluid reservoir.
  7. Bleed the brake system. Refer to Hydraulic Brake System Bleeding.

    8. Top up the brake fluid reservoir to the MAX marking. Refer to Master Cylinder Reservoir Filling.

  8. Install the cover on to the brake fluid reservoir.