Solstice 2006-2008, Sky 2007-2008

Master Cylinder

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Removal & Installation



With Active Brake Control System (Jl4)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. With the engine OFF, apply the brake pedal several times until the brake pedal becomes firm to deplete the vacuum brake booster vacuum reserve.
  4.  
  5. If equipped, disconnect the clutch master cylinder hose from the brake master cylinder reservoir.
  6.  
  7. Cap the brake fluid reservoir outlet and plug the clutch master cylinder hose inlet to prevent brake fluid loss and contamination.
  8.  
  9. Disconnect the brake fluid level sensor electrical connector.
  10.  
  11. Remove brake lines. Cap the brake pipe fittings and plug the master cylinder outlet ports to prevent brake fluid loss and contamination.
  12.  
  13. Remove the master cylinder mounting nuts and discard.
  14.  
  15. Remove the brake master cylinder.
  16.  
  17. When removing the master cylinder, ensure the master cylinder to booster seal between the vacuum booster and the master cylinder is properly seated in the groove at the rear of the master cylinder and is not damaged. Replace the seal if necessary

    Click image to see an enlarged view

    Fig. Master cylinder (JL4) and related parts

  18.  

To install:

  1. If installing a new master cylinder, bench bleed the master cylinder.
  2.  
  3. Install brake master cylinder.
  4.  
  5. Install new mounting bolts to 11 ft. lbs. (15 Nm).
  6.  
  7. Install brake lines and tighten to 15 ft. lbs. (20 Nm)
  8.  
  9. Fill the master cylinder reservoir.
  10.  
  11. Bleed the brake system.
  12.  

Without Active Brake Control System (Jl4)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. With the engine OFF, apply the brake pedal several times until the brake pedal becomes firm to deplete the vacuum brake booster vacuum reserve.
  4.  
  5. If equipped, disconnect the clutch master cylinder hose from the brake master cylinder reservoir.
  6.  
  7. Cap the brake fluid reservoir outlet and plug the clutch master cylinder hose inlet to prevent brake fluid loss and contamination.
  8.  
  9. Disconnect the brake fluid level sensor electrical connector.
  10.  
  11. Remove brake lines. Cap the brake pipe fittings and plug the master cylinder outlet ports to prevent brake fluid loss and contamination.
  12.  
  13. Remove the master cylinder mounting nuts and discard.
  14.  
  15. Remove the brake master cylinder.
  16.  
  17. When removing the master cylinder, ensure the master cylinder to booster seal between the vacuum booster and the master cylinder is properly seated in the groove at the rear of the master cylinder and is not damaged. Replace the seal if necessary

    Click image to see an enlarged view

    Fig. Master cylinder (w/o JL4) and related parts

  18.  

To install:

  1. If installing a new master cylinder, bench bleed the master cylinder.
  2.  
  3. Install brake master cylinder.
  4.  
  5. Install new mounting bolts to 11 ft. lbs. (15 Nm).
  6.  
  7. Install brake lines and tighten to 15 ft. lbs. (20 Nm)
  8.  
  9. Fill the master cylinder reservoir.
  10.  
  11. Bleed the brake system.
  12.  

 
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