On the market from 1982 to 2005, the Chevy Cavalier was General Motor's response to customers needing a compact, fuel-efficient vehicle. The Cavalier uses many of the same parts as other GM vehicles, making the prices and availability of parts very appealing. As with any vehicle, proper care and servicing must be followed to ensure continued safety and performance. At times, it may be necessary to replace certain components, such as the brake system master cylinder. Fortunately, the process is fairly simple.
Raise the hood and locate the master cylinder on the driver's side of the firewall. Find the electrical connector that is attached to it and remove it.
Slide a drain pan underneath the master cylinder. This will catch any falling brake fluid. Remove the brake lines from the cylinder with a wrench. Be sure to install plugs into these lines to avoid contamination.
Remove the cylinder assembly by removing the nuts that hold it to the firewall. Loosen these nuts with a wrench. On some vehicles, the cylinder may be attached to a brake booster in the same manner.
Install the new master cylinder to the brake booster or firewall. Secure it with the nuts and tighten them to 22 to 30 foot-pounds.
Remove the plugs on the ends of the brake lines. Attach the lines to the master cylinder, but do not over-tighten them. Tighten them to 10-15 foot-pounds with a torque wrench.
Locate the electrical cable and reattach it to the master cylinder.
Fill the brake reservoir with brake fluid and prepare to bleed the brakes.
Bleed the break system of air. This is done with help of an assistant. Have your assistant depress the brake pedal and hold it. Open the bleed ports located on or near the brake calipers with a wrench. Allow fluid to come out of the port. Close the bleed port and stop pressing the brake pedal. Repeat this process until there are no more air bubbles coming from the bleed port. Continue to monitor the fluid level in the master cylinder as this process moves along.
Test-drive the vehicle to make sure the brakes operate properly.
