GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 SL 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Master Cylinder Reservoir Replacement

Removal Procedure

    Object Number: 866702 Size: SH
  1. Remove the master cylinder from the vehicle. Refer to Master Cylinder Replacement or Brake Modulator/Master Cylinder Assembly Replacement .

    2. Important: Base brake master cylinder shown. ABS master cylinder procedure is similar.

  2. Wipe the reservoir cap clean.
  3. Remove the cap, and inspect the reservoir cap and diaphragm for the following conditions:
    4. • Cuts
    • Cracks
    • Nicks
    • Deformation
    • Replace any damaged parts.
  4. Empty brake fluid from the reservoir.
  5. Remove the brake fluid level switch.

    6. Object Number: 872266 Size: SH
  6. Place the master cylinder in a vise as shown in the illustration.

    7. Important: Do not clamp on the master cylinder body.

  7. Drive out spring pins, using a suitable 1/8 in punch.
  8. Pull the reservoir out of the cylinder body.
  9. Remove the O-rings from the grooves in the reservoir bayonets.
  10. Clean the reservoir with clean denatured alcohol and inspect the reservoir for cracks or deformation. Replace if damaged. The reservoir can be blown dry with a non-lubricated, low-pressure air hose.

Installation Procedure
  1. Lubricate the new O-rings and bayonets with clean brake fluid and install the O-rings into the bayonet grooves.
  2. Install the reservoir into the master cylinder body by pressing the reservoir straight into the cylinder body by hand.

    3. Object Number: 872279 Size: SH
  3. Drive in the reservoir retention spring pins.

    4. Notice: Use care not to damage reservoir or cylinder body when driving in pins.

  4. Install the brake fluid level switch.
  5. Install the master cylinder into the vehicle. Master Cylinder Replacement or Brake Modulator/Master Cylinder Assembly Replacement .