GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 L100/L200/LW200 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Master Cylinder Replacement

Removal Procedure

    Object Number: 895463 Size: SH

    Notice: Brake fluid is corrosive to painted surfaces. Take care not to allow brake fluid to contact painted surfaces on vehicle.

  1. Vehicles equipped with manual transaxles must disconnect the clutch hydraulic feed line from the master cylinder reservoir. Plug the line to avoid leakage and contamination.
  2. Remove the low brake fluid sensor electrical connector.

    3. Important: After removing brake pipe nuts, do not excessively pull or bend brake pipes away from master cylinder.

  3. Remove the brake pipe fittings from the master cylinder.

    4. Important: Plug open brake pipes to prevent brake fluid loss and contamination.


    Object Number: 891661 Size: SH
  4. Remove the master cylinder to brake booster nuts.

    5. Notice: Do not bend brake pipes.

  5. Remove the master cylinder.

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 891661 Size: SH
  1. Position the master cylinder onto the booster studs and install the nuts.

    2. Tighten
    Tighten the cylinder-to-brake booster nuts to 25 N·m (18 lb ft).


    Object Number: 891660 Size: SH

    Notice: Do not bend brake pipes.

  2. Position the brake pipes into the master cylinder and tighten the nuts.

    3. Tighten
    Tighten the brake pipe-to-master cylinder nuts to 16 N·m (12 lb ft).


    Object Number: 895463 Size: SH
  3. Vehicles equipped with manual transaxles must install the clutch hydraulic feed line to the master cylinder.
  4. Connect the low brake fluid switch electrical connector.

    5. Notice: Refer to Brake Fluid Caution in the Preface section.

  5. Fill the brake fluid reservoir with clean brake fluid up to the MAX mark on the reservoir.
  6. Bleed the brake system. Refer to Hydraulic Brake System Bleeding .