Grand AM L4-138 2.3L DOHC VIN D MFI (1994)
DISASSEMBLE
Refer to Figs. 19 and 20 when performing the following procedures.
1. Remove master cylinder from vehicle as follows:
a. Disconnect and plug hydraulic lines.
b. Remove two master cylinder attaching nuts, then the master cylinder.
2. Remove reservoir cover and diaphragm. Discard old brake fluid in reservoir.
3. Inspect cover and diaphragm. Replace if cut, cracked or deformed.
4. Remove fluid level switch, if equipped.
5. On models with compact master cylinder, remove proportioner valve assembly, Fig. 20.
6. On all models, depress primary piston and remove lock ring.
7. Plug primary fluid outlet (outlet nearest to cowl when master cylinder is installed), then apply compressed air into secondary fluid outlet to remove
primary and secondary pistons.
8. Remove spring retainer and seals from secondary piston.
9. Clamp master cylinder in a vise as shown in Fig. 21, then remove reservoir using a pry bar. Remove reservoir grommets.
10. Inspect master cylinder bore for corrosion. Do not use abrasive material on master cylinder bore. Replace if bore is corroded.
ASSEMBLE
Clean all parts not included in repair kit with brake fluid. Do not dry with compressed air. Lubricate all rubber parts with clean brake fluid prior to
installation.
1. Lubricate new reservoir grommets with silicone brake lube, then press grommets into master cylinder body. Ensure grommets are properly seated.
2. Lay reservoir upside down on flat, hard surface. Press master cylinder body onto reservoir using rocking motion.
3. Install new seals on secondary piston, then the spring retainer.
4. Install spring and secondary piston assembly into cylinder.
5. Install primary piston. Depress primary piston into cylinder, then install lock ring.
6. Install fluid level switch, if equipped.
7. On models with compact master cylinder, install proportioner valve assembly, Fig. 20.
8. On all models, fit diaphragm into reservoir cover, then install cover onto reservoir.
9. Install master cylinder and bleed brake system.
Master Cylinder Replace
1. Disconnect wire connector from brake warning pressure switch, if equipped.
2. Disconnect brake lines from master cylinder.
3. Remove master cylinder mounting nuts, then the master cylinder.
4. On models with separate fluid reservoirs, remove reservoir.
5. On all models, reverse procedure to install, noting the following:
a. Refer to Master Cylinder Push Rod for procedures on push rod adjustments.
b. Bleed brakes as described under Brake Bleeding. Refer to Brakes/Service and Repair.
