Hydraulic Control Assembly - Antilock Brakes: Service and Repair

Modulator Unit

Service Repair No - 70.65.49

Remove

1. Remove engine acoustic cover if fitted.





2. Release and remove air intake hose.
3. Release clip securing harness and intake duct to body.
4. Lift duct from body, release clip from washer reservoir filler hose.
5. Release and remove air intake duct.





6. Td4 models only: Loosen 2 clips and remove intercooler outlet hose.





7. Remove 2 bolts securing PAS oil cooler pipes.
8. Release PAS reservoir from mounting bracket and position aside.





9. Release catch and disconnect ABS modulator multiplug.
10. Position cloth under modulator to absorb fluid spillage.

CAUTION: Brake fluid will damage paint finished surfaces. If spilled, immediately remove fluid and clean area with water.

11. Disconnect 2 inlet brake pipes unions from ABS modulator.
12. Disconnect 4 outlet brake pipes unions from ABS modulator.

CAUTION: Always fit plugs to open connections to prevent contamination.

13. Remove 3 bolts securing ABS modulator to mounting bracket.
14. Release and remove ABS modulator from mounting bracket.

Refit
1. Position modulator to mounting bracket fit bolts and tighten to 13 Nm (9.5 ft. lbs.).
2. Clean brake pipe unions.
3. Connect brake pipe unions to modulator ensuring pipes are connected to their correct ports.
4. Tighten unions to 17 Nm (12 ft. lbs.).
5. Connect ABS modulator multiplug and secure catch.
6. Position air intake duct to body.
7. Secure intake duct to washer bottle filler neck and harness clip.
8. Fit air intake hose.
9. Fit PAS reservoir to mounting bracket.
10. Fit bolts securing PAS oil cooler pipes and tighten to 10 Nm (7.5 ft. lbs.).
11. Td4 models only: Fit intercooler outlet hose and tighten clips.
12. Fit engine acoustic cover.
13. Bleed brakes.
14. To ensure correct operation, the ABS system MUST be tested using TestBook.