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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 117 (HYDRAULIC BRAKE SYSTEM)REPAIR INSTRUCTIONSMASTER CYLINDER REPLACEMENTINSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Installation Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Installation Procedure
WARNING: This page is about a different car, the 2008 Chevrolet Malibu Classic. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the brake master cylinder reservoir to the master cylinder if it was removed previously. Refer to Master Cylinder Reservoir Replacement .
  2. Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding .
  3. Check to ensure that the master cylinder-to-vacuum brake booster seal is properly seated on the master cylinder barrel.
    4. Fig 1: View Of Master Cylinder Mounting Nuts
    GM1219209Courtesy of GENERAL MOTORS CORP.
  4. Install the master cylinder to the vacuum brake booster.
    5. NOTE: Refer to Fastener Notice .
  5. Install the 2 brake master cylinder mounting nuts.

    Tighten:  Tighten the 2 brake master cylinder mounting nuts to 25 N.m (18 lb ft).

  6. Remove the plugs from the brake pipes.
    7. Fig 2: View Of Brake Pipes At Master Cylinder
    GM1219526Courtesy of GENERAL MOTORS CORP.
  7. Install the brake pipes to the master cylinder.

    Tighten:  Tighten the brake pipe fittings at the master cylinder to 20 N.m (15 lb ft).

  8. Connect the electrical connector to the brake fluid level sensor.
    9. Fig 3: Identifying Vacuum Check Valve, Vacuum Brake Booster Grommet And Vacuum Brake Hose
    GM1222406Courtesy of GENERAL MOTORS CORP.
  9. Connect the vacuum brake booster check valve (1) to the vacuum brake booster grommet (4).
  10. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Pressure)  or Hydraulic Brake System Bleeding (Manual) .
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.