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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1941 (Hydraulic Brake System) >> Repair Instructions >> Master Cylinder Replacement (With RPO HP5) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2009 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Refer to Brake Fluid Irritant Warning .
CAUTION: Refer to 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.
    2. 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. Remove the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement (HP7) or Underhood Electrical Center or Junction Block Replacement (HP5) .
  5. Without draining the coolant or disconnecting the hoses, remove and position aside the radiator surge tank. Refer to Radiator Surge Tank Replacement .
  6. Disconnect the brake fluid level sensor electrical connector.
    7. Fig 1: Brake Master Cylinder Reservoir Supply And Return Hose Quick Connect Fittings
    GM2193334Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the brake master cylinder reservoir supply hose quick connect (1) and position the hose aside.
  8. Disconnect the brake master cylinder reservoir return hose quick connect (2) and position the hose aside.
    9. Fig 2: Rear Brake Pipe Fittings
    GM2193340Courtesy of GENERAL MOTORS CORP.
    NOTE: Mark the location of the brake pipes to the master cylinder to ensue correct installation.
  9. Disconnect the brake master cylinder rear brake pipe fittings (1).

    Cap the brake pipe fittings and plug the master cylinder outlet ports to prevent brake fluid loss and contamination.

    10. Fig 3: Front Brake Pipe Fittings
    GM2193341Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the brake master cylinder front brake pipe fittings (1).

    Cap the brake pipe fittings and plug the master cylinder outlet ports to prevent brake fluid loss and contamination.

    11. Fig 4: Master Cylinder Primary Brake Pipe Fitting
    GM2193342Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the brake master cylinder primary brake pipe fitting (1).

    Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.

    12. Fig 5: Brake Master Cylinder Nuts
    GM2193345Courtesy of GENERAL MOTORS CORP.
  12. Remove the brake master cylinder nuts (1).

    Discard the brake master cylinder nuts.

    13. Fig 6: Brake Master Cylinder
    GM2193346Courtesy of GENERAL MOTORS CORP.
  13. Remove the brake master cylinder (1).
  14. Remove the brake master cylinder O-ring seal (2).
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