GM Cavalier/Sunfire 1995-2000 Repair Guide

Master Cylinder

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3



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Fig. Fig. 1: Disconnecting the master cylinder-to-actuator cylinder hydraulic line



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Fig. Fig. 2: Clutch master cylinder mounting

Service this vehicle with Hydraulic Clutch Fluid GM P/N 12345347 or equivalent.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the sound insulator from inside the vehicle.
  4.  
  5. Disconnect the clutch master cylinder pushrod from the clutch pedal.
  6.  
  7. Unfasten the clutch master cylinder retaining nuts at the front of the cowl, then remove the remote reservoir.
  8.  
  9. Detach the master cylinder assembly from the actuator cylinder by disconnecting the hydraulic line, then remove the master cylinder from the vehicle.
  10.  



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Fig. Fig. 3: Connecting the master cylinder-to-actuator cylinder hydraulic line

To install:
  1. Attach the master cylinder to the actuator cylinder by fastening the hydraulic line.
  2.  
  3. Install the remote fluid reservoir, then secure with the retaining nuts. Tighten the nuts evenly to 18 ft. lbs. (25 Nm).
  4.  
  5. Connect the pushrod to the clutch pedal. If equipped, adjust the cruise control switch, as outlined in Chassis Electrical of this guide.
  6.  
  7. Install the sound insulator.
  8.  
  9. Bleed the hydraulic system, as outlined later in this section.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Road test the vehicle and verify proper operation.
  14.  

 
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