Master Cylinder Reservoir Replacement (Two-Mode Hybrid)

Master Cylinder Reservoir Replacement (Two-mode Hybrid)

Removal Procedure
Warning: Refer to Brake Fluid Irritant Warning (Brake Fluid Irritant Warning).


Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (Brake Fluid Effects on Paint and Electrical Components Caution).

Note: The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes.

1. Turn the ignition to OFF, without pausing at ACCESSORY, and remove the ignition key.

Note: During the pressure relief process, the fluid level in the master cylinder reservoir will rise. Do not remove the master cylinder reservoir cap during the pressure relief process.

2. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete.
3. Remove the brake fluid from the brake master cylinder reservoir and discard into an approved container.
4. Disconnect the brake fluid level sensor electrical connector.




5. Disconnect the brake master cylinder reservoir return hose quick connect (1) and position the hose aside.
6. Disconnect the brake master cylinder reservoir supply hose quick connect (2) and position the hose aside.




7. Remove the brake master cylinder reservoir pins (1).




8. Lift the master cylinder reservoir (1) straight up and remove the reservoir from the master cylinder.




9. Remove the 3 master cylinder reservoir seals (1).

Installation Procedure




1. Install the 3 master cylinder reservoir seals (1).
Lubricate the master cylinder reservoir seals and the outer surface area of the reservoir-to-housing barrels with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.




2. Install the master cylinder reservoir (1) to the master cylinder.
Ensure the master cylinder reservoir is seated fully into the master cylinder by pressing the reservoir straight down into the master cylinder.

Caution: Refer to Fastener Caution (Fastener Caution).




3. Install the brake master cylinder reservoir pins (1) and tighten to 8 Nm (71 lb in).




4. Connect the brake master cylinder reservoir return hose quick connect (1).
5. Connect the brake master cylinder reservoir supply hose quick connect (2).
6. Connect the brake fluid level sensor electrical connector.
7. Fill the brake master cylinder reservoir. Refer to Master Cylinder Reservoir Filling (Master Cylinder Reservoir Filling).