Hydraulic Control Assembly - Antilock Brakes: Service and Repair

ABS (ESP(R)) Hydraulic Unit / Control Module Assembly Removal and Installation

CAUTION:
Never disassemble ABS (ESP(R)) hydraulic unit / control module assembly, loosen blind plug or remove motor. Performing any of these prohibited services will affect original performance of ABS (ESP(R)) hydraulic unit / control module assembly.








Removal
1. Disconnect negative (-) cable from battery.
2. Remove ECM.
3. Disconnect ABS ESP(R) control module connector as shown in figure.








4. Using special tool, loosen flare nuts (1) and disconnect brake pipes (2) from ABS ESP(R) hydraulic unit/ control module assembly (3).
Special Tool
(A):09950-78220

NOTE:
Put bleeder plug cap or the like onto pipe to prevent fluid from spilling. Do not allow brake fluid to get on painted surfaces. I

5. Disconnect harness clamps (4) from bracket (5).





6. Remove ABS ESP(R) hydraulic unit / control module with bracket from vehicle by removing bracket bolt and two bracket nuts.
7. Remove bolt and pull out ABS ESP(R) hydraulic unit / control module assembly (1) from bracket (3) using flat end rod or the like (2).

CAUTION:
^ Do not give an impact to hydraulic unit.
^ Use care not to allow dust to enter hydraulic unit.
^ Do not place hydraulic unit on its side or upside down. Handling it in inappropriate way will affect its original performance.





Installation
1. Install hydraulic unit / control module assembly by reversing removal procedure.
Tightening torque
Brake pipe flare nut for M10 (a): 16 Nm (1.6 kg-m, 11.5 ft. lbs.)
Brake pipe flare nut for M12 (b): 19 Nm (1.9 kg-m, 14.0 ft. lbs.)
ABS (ESP(R)) hydraulic unit / control module assembly bolt (c): 9 Nm (0.9 kg-m, 6.5 ft. lbs.)
ABS (ESP(R)) hydraulic unit / control module assembly bracket bolt (d): 25 Nm (2.5 kg-m, 18.0 ft. lbs.)
ABS (ESP(R)) hydraulic unit / control module assembly bracket nut: 25 Nm (2-5 kg-m, 18.0 ft. lbs.)








2. Connect ABS ESP(R) control module connector and lock it as shown in figure.








3. Connect harness clamp to bracket.
4. Install ECM.
5. Connect negative (-) cable at battery.
6. Bleed air from brake system.
7. Check each installed part for fluid leakage.
8. For ESP(R) model, perform Sensor Calibration.
9. Perform Hydraulic Unit Operation Check.
10. Turn ignition switch to OFF position once and then ON position. In this state, make sure that all indicator lights are turn off.
11. Check DTC(s) are not stored in hydraulic unit / control module.