Chevrolet Sonic Repair Manual: Master Cylinder Replacement
- Removal Procedure
-
Warning:
Refer to Brake Fluid Irritant Warning.
Caution:
Refer to Brake Fluid Effects on Paint and Electrical Components Caution.
- Place the ignition switch in the OFF position.
- Remove the battery. Refer to Battery Replacement.
- Disconnect the brake fluid level indicator switch electrical connector.
- Using a suitable suction device, remove and properly discard the brake fluid from the brake master cylinder reservoir.
- On manual transmission equipped vehicles, disconnect the clutch master cylinder reservoir hose. Refer to Clutch Master Cylinder Reservoir Hose Replacement
- Disconnect the master cylinder secondary brake pipe fitting (1).
- Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.
- Disconnect the master cylinder primary brake pipe fitting (1).
- Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.
- Remove the master cylinder nuts (1).
- Remove the brake master cylinder.
- Remove the master cylinder seal (1).
- Inspect the master cylinder seal for damage or deterioration and replace, if necessary.
- Remove the brake fluid level indicator switch, if necessary. Refer to Brake Fluid Level Indicator Switch Replacement.
- Remove the master cylinder reservoir, if necessary. Refer to Master Cylinder Reservoir Replacement.
- Installation Procedure
-
- Install the master cylinder reservoir, if removed. Refer to Master Cylinder Reservoir Replacement.
- Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding.
- Install the brake fluid level indicator switch, if removed. Refer to Brake Fluid Level Indicator Switch Replacement.
- Install the master cylinder seal (1).
- Install the master cylinder to the power vacuum brake booster.
- Install the master cylinder nuts (1) and tighten to 50 Y (37 lb ft)
.
- Connect the master cylinder primary brake pipe fitting (1) and tighten
to 18 Y (13 lb ft)
.
- Connect the master cylinder secondary brake pipe fitting (1) and tighten
to 18 Y (13 lb ft)
.
- On manual transmission equipped vehicles, connect the clutch master cylinder reservoir hose. Refer to Clutch Master Cylinder Reservoir Hose Replacement
- Connect the brake fluid level indicator switch electrical connector.
- Install the battery. Refer to Battery Replacement.
- Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding.
Caution:
Refer to Fastener Caution.
Master Cylinder Bench Bleeding
Warning: Refer to Brake Fluid Irritant Warning.
Caution: Refer to Brake Fluid Effects on Paint and Electrical
Components Caution.
Secure the mounting flange of the bra ...
Special Tools
Illustration
Tool Number/ Description
CH 28662
J 28662
Brake Pedal Effort Gauge
...
Other materials:
Backup Lamp Bulb Replacement (Sedan)
Backup Lamp Bulb Replacement
Callout
Component Name
Preliminary Procedure
Remove the tail lamp assembly. Refer to Tail Lamp Replacement.
1
Back Up Lamp Bulb Socket
Procedure
Rotate the back u ...
Tire-to-Wheel Match-Mounting (Vectoring)
Note: After remounting a tire to a wheel or after replacing a tire
and/or a wheel, remeasure the tire and wheel assembly runout in order to verify
that the amount of runout has been reduced and brought to within tolerances.
Ensure that the tire and wheel assembly is properly balanced ...
Range Selector Lever Cable Bracket Replacement
Removal Procedure
Set the park brake and chock the wheels.
Disconnect the range selector cable end (1) from the
range selector lever.
Disconnect the range selector cable (2) from the range
selector cable bracket.
Remove the transmission rang ...
0.008