Hydraulic Modulator Assembly Removal and Instalation

Master Cylinder-Modulator Assembly

WARNING: To avoid personal injury, due to a retained load on the modulator assembly, the "Gear Tension Relief" function of the TECH 1 scan tool must be performed prior to removal of the brake control and motor assembly.

Remove or Disconnect

ABS Hydraulic Modulator Assembly Removal:

1. Using Tech 1, perform "Gear Tension Relief Sequence".

2. Air cleaner.
3. Upper fuel lines and set aside.
4. Two solenoid electrical connectors.
5. Fluid level sensor electrical connector.
6. 6-pin ABS motor pack electrical connectors.

Brake Pipe Connections:

7. Four brake pipes.
^ Place shop cloth on top of motor pack to catch any dripping fluid. Take care not to allow brake fluid to enter the bottom of the motor pack or the electrical connectors. Plug open lines to prevent fluid loss and contamination.
8. Two nuts attaching ABS hydraulic modulator/master cylinder assembly to vacuum booster.
^ It may be necessary to remove vacuum check valve from vacuum booster to gain access to the nut closest to the check valve.
9. ABS Hydraulic modulator/master cylinder assembly from vehicle.


Install or Connect

ABS Hydraulic Modulator Assembly Removal:

1. Hydraulic modulator/master cylinder assembly in vehicle.
^ It may be necessary to remove vacuum check valve from vacuum booster to gain access to the nut closest to the check valve.
2. Two nuts attaching hydraulic modulator/master cylinder assembly to vacuum booster.

Tighten
^ Hydraulic modulator/master cylinder mounting nuts to 27 Nm (20 lb.ft.).

3. Four brake pipes to ABS hydraulic modulator/master cylinder assembly.

Tighten
^ Brake pipe tube nuts to 24 Nm (18 lb.ft.).

4. ABS motor pack 6-pin electrical connector.
5. Fluid level sensor electrical connector.
6. Two solenoid electrical connectors.
7. Upper fuel lines.

Important
^ Bleed system.