GM Corsica/Beretta 1988-1996 Repair Guide

Master Cylinder

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REMOVAL & INSTALLATION




WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint.

1988-91 Vehicles

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Detach the electrical connector from the fluid level sensor.
  4.  
  5. Disconnect and cap or plug the four (4) brake lines on the master cylinder.
  6.  
  7. Remove the master cylinder-to-power booster nuts, then remove the master cylinder with the reservoir attached from the vehicle.
  8.  



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Fig. Fig. 1: Exploded view of the brake master cylinder-to-power booster attachment - 1988-91 vehicles

To install:
  1. Position the master cylinder and tighten the retaining nuts to 20 ft. lbs. (27 Nm).
  2.  
  3. Uncap the brake lines, then connect them to the master cylinder and tighten to 13-15 ft. lbs. (17-20 Nm).
  4.  
  5. Attach the fluid level electrical sensor wires.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Refill the reservoir with an approved DOT 3 brake fluid and bleed the brake system.
  10.  

1992-96 Vehicles

See Figure 2, 3, 4, 5, 6 and 7

  1. Disconnect the negative battery cable.
  2.  



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Fig. Fig. 2: Detach the solenoid electrical connectors



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Fig. Fig. 3: Unplug the fluid level electrical connector

  1. Unplug the electrical connectors from both solenoids.
  2.  
  3. Detach the electrical connector from the fluid level sensor.
  4.  
  5. Detach the 3-pin and 6 pin motor pack electrical connectors.
  6.  
  7. Disconnect and cap the four (4) brake lines from the master cylinder and modulator.
  8.  



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Fig. Fig. 4: Place a shop rag under the fittings, then disconnect and plug the brake lines from the master cylinder

  1. Remove the master cylinder-to-power booster bolts/nuts and remove the master cylinder and modulator assembly.
  2.  



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Fig. Fig. 5: Unfasten the master cylinder/hydraulic modulator-to-power booster retainers ...



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Fig. Fig. 6: ... then remove the master cylinder/hydraulic modulator assembly from its mounting



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Fig. Fig. 7: Brake master cylinder/ABS hydraulic modulator mounting - 1992-96 vehicles

To install:
  1. Position the master cylinder and tighten the retaining nuts to 20 ft. lbs. (27 Nm). and the brake lines-to-master cylinder and modulator to 15 ft. lbs. (20 Nm).
  2.  
  3. Connect the fluid level electrical sensor wires.
  4.  
  5. Attach the electrical connectors to both solenoids.
  6.  
  7. Connect the 3-pin and 6 pin motor pack electrical connectors.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Refill the reservoir with an approved DOT 3 brake fluid and bleed the brake system.
  12.  

 
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