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.

1. Place the ignition switch in the OFF position.
2. Remove the battery. Refer to Battery Replacement.
3. Disconnect the brake fluid level indicator switch electrical connector.
4. Using a suitable suction device, remove and properly discard the brake fluid from the brake master cylinder reservoir.
5. On manual transmission equipped vehicles, disconnect the clutch master cylinder reservoir hose. Refer to Clutch Master Cylinder Reservoir Hose Replacement



6. Disconnect the master cylinder secondary brake pipe fitting (1).
7. Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.


8. Disconnect the master cylinder primary brake pipe fitting (1).
9. Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.


10. Remove the master cylinder nuts (1).
11. Remove the brake master cylinder.


12. Remove the master cylinder seal (1).
13. Inspect the master cylinder seal for damage or deterioration and replace, if necessary.
14. Remove the brake fluid level indicator switch, if necessary. Refer to Brake Fluid Level Indicator Switch Replacement.
15. Remove the master cylinder reservoir, if necessary. Refer to Master Cylinder Reservoir Replacement.

Installation Procedure

1. Install the master cylinder reservoir, if removed. Refer to Master Cylinder Reservoir Replacement.
2. Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding.
3. Install the brake fluid level indicator switch, if removed. Refer to Brake Fluid Level Indicator Switch Replacement.



4. Install the master cylinder seal (1).
5. Install the master cylinder to the power vacuum brake booster.



Caution:

Refer to Fastener Caution.

6. Install the master cylinder nuts (1) and tighten to  50 Y (37 lb ft)

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7. Connect the master cylinder primary brake pipe fitting (1) and tighten to  18 Y (13 lb ft)

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8. Connect the master cylinder secondary brake pipe fitting (1) and tighten to  18 Y (13 lb ft)

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9. On manual transmission equipped vehicles, connect the clutch master cylinder reservoir hose. Refer to Clutch Master Cylinder Reservoir Hose Replacement
10. Connect the brake fluid level indicator switch electrical connector.
11. Install the battery. Refer to Battery Replacement.
12. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding.

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