Master Cylinder Reservoir Replacement

Master Cylinder Reservoir Replacement (Without RPO HP5)

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 (Vehicle Damage Warnings).

1. Using a suitable tool, remove the brake fluid from the brake master cylinder reservoir.
2. Discard the brake fluid into an approved container.
3. Remove the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement (HP7) (Service and Repair)Underhood Electrical Center or Junction Block Replacement (HP5) (Service and Repair).
4. Without draining the coolant or removing the hoses, remove and position aside the radiator surge tank. Refer to Radiator Surge Tank Replacement (Service and Repair).




5. Disconnect the master cylinder fluid level sensor electrical connector (1).
6. Remove the master cylinder reservoir retaining pins (2) by compressing the locking tabs.
Discard the retaining pins.




7. Carefully remove the master cylinder reservoir (1) by pulling the reservoir straight up.




8. Remove the master cylinder reservoir seals (1).

Installation Procedure




1. Install the master cylinder reservoir seals (1).




2. Install the master cylinder reservoir (1) to the master cylinder.
Ensure the master cylinder reservoir bayonets are fully seated in the master cylinder.




3. Connect the master cylinder fluid level sensor electrical connector (1).
4. Install new master cylinder reservoir retaining pins (2).
Ensure the retaining pins are fully seated and the locking tabs are fully deployed.
5. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement (Service and Repair).
6. Install the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement (HP7) (Service and Repair)Underhood Electrical Center or Junction Block Replacement (HP5) (Service and Repair).
7. Fill the master cylinder reservoir to the proper level. Refer to Master Cylinder Reservoir Filling (Without RPO HP5) (Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (With RPO HP5) (Master Cylinder Reservoir Filling).
8. Observe the brake pedal feel after filling the master cylinder reservoir. If the pedal feels spongy, bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (Service and Repair)Hydraulic Brake System Bleeding (Pressure) (Service and Repair).