Hydraulic Control Assembly - Antilock Brakes: Service and Repair

Hydraulic System Layout (With ABS):

NOTE: Refer to the illustration for details of modulator unit and hydraulic pipe connections to it.

CAUTION:
^ New modulator units are supplied in a shock absorbing pack, marked with a "use by" date. The new modulator will contain hydraulic brake fluid within the valve block and have all ports plugged.
^ Modulator units must be handled with care, the following must be avoided:
- Any impact
- Use of compressed air on any of the hydraulic ports
- Removing plugs to connection ports before fitting unit

REMOVAL
1. Check new modulator unit is packaged in accordance with the CAUTION above.
2. Disconnect battery negative lead.
3. Remove the two electrical plugs.
4. Identify 8 pipe to modulator connections for correct reassembly.
5. Disconnect 8 pipe unions.
6. Remove nuts securing modulator to mounting bracket.
7. Remove modulator unit.
8. Remove mounting bushes and cup.

INSTALLATION
1. Install mounting bushes and cup to new modulator.
2. Install modulator unit to mounting bracket.
3. Install 8 pipes to modulator connections. Pipes must be connected to correct port. Tighten to 15 Nm (11 ft. lbs.).
4. Bleed the complete hydraulic system. Service and Repair
5. Check system function.
6. Test operation of brakes.