Motor Pack

CAUTION: To help avoid personal injury, due to a retained load on the ABS hydraulic modulator, the gear tension relief function of the Tech 1 must be performed prior to removal of the ABS hydraulic modulator/master cylinder assembly. Refer to "Gear Tension Relief Sequence".

NOTICE: Complete overhaul of the hydraulic modulator/master cylinder assembly is not authorized, only the following steps. These steps will break the unit down into major components for replacement purposes.

MOTOR PACK

Hydraulic Modulator/Master Cylinder Assembly:

DISASSEMBLE
1. Air cleaner duct clamps and electrical connection.
2. Battery from vehicle.
3. Clip from engine compartment fuse/relay center.
4. Remove air box assembly.
5. Disconnect motor pack electrical connector.
6. Two (2) Torx head screws attaching gear cover.
7. Remove gear cover.
8. Four Torx head screws attaching motor pack to hydraulic modulator.
9. Motor pack from hydraulic modulator.

NOTICE: It is necessary to slightly bend brake pipes out of the way to allow for removal of motor pack.

IMPORTANT:
^ Use care when handling motor pack to ensure motor pack connector is not damaged, or accidental intrusion of brake fluid into the motor pack does not occur. This may result in a premature failure of the motor pack.
^ Take care in handling the motor pack. If dropped or damaged during handling, the motor pack must be replaced.
^ If disassembly of the hydraulic modulator/master cylinder assembly was due to a ABS hydraulic functional test that did not pass, the "Automated Motor Pack Diagnosis Test" should be performed at this time to isolate the motor pack or hydraulic modulator.
^ No repair of the motor pack is authorized. Replace as an assembly.

ASSEMBLE
1. Motor pack to hydraulic modulator, reposition brake pipes.

IMPORTANT
^ Take care in handling the motor pack. If dropped or damaged during handling the motor pack must be replaced.
^ Align each of the three motor pack pinions with the hydraulic modulator gears.

2. Four Torx head screws.

TIGHTEN
^ Torx head screws to 5 Nm (44 lb. in.).

3. Gear cover to hydraulic modulator/master cylinder assembly.
4. Torx head screws attaching gear cover.

TIGHTEN
^ Torx bolts to 4 Nm (36 lb. in.).

5. Connect motor pack electrical connector.
6. Install air box assembly.
7. Clip to engine compartment fuse/relay center.
8. Battery to vehicle.
9. Air cleaner duct clamps and electrical connections.
10. Using Tech 1, perform "rehome" procedure.