Hydraulic Control Assembly - Antilock Brakes: Service and Repair
REMOVAL
1. Remove air cleaner housing cover and air induction hose at throttle body.
2. Remove two powertrain control module bolts.
3. Disconnect powertrain control module I/P harness electrical connector.
4. Lift powertrain control module from carrier and set aside.
5. Disconnect brake fluid level switch connector.
6. Disconnect electronic brake and traction control module electrical connector by pulling on lock tab.
NOTICE: Clean brake pipe fittings to prevent contaminants entering ABS system. Place shop cloth underneath brake pipes to catch dripping brake fluid.
7. Disconnect brake pipe nuts from brake pressure modulator valve.
NOTICE: Take care in not to pull or bend brake pipes away from pressure modulator valve.
NOTICE: Plug open brake pipes with plastic fittings to prevent brake fluid loss and contamination.
8. Remove ABS control assembly-to-rail attachment bolt.
9. Pull ABS assembly forward to disengage tab from bracket, then remove from vehicle.
DISASSEMBLY
1. Use Saturn Brake Cleaner (or equivalent) to clean brake fluid from ABS control unit.
2. Place Electro-Static Discharge (ESD) Pad on clean bench and connect ground strap to ground connection on work bench.
3. Put ESD wrist strap on and attach ground strap to same ground used for ESD pad.
4. Remove four screws from the electronic brake and traction control module.
5. Separate the electronic brake and traction control module from the brake pressure modulator valve by pulling straight back.
ASSEMBLY
1. Align coils on electronic brake and traction control module with valve cores on brake pressure modulator valve and push together.
2. Inspect gasket on electronic brake and traction control module for damage. If gasket is damaged, refer to "Gasket Repair".
3. Install and torque four screws to the electronic brake and traction control module.
Torque: 4 - 6 Nm (35 - 53 inch lbs.)
REPAIR PROCEDURE FOR EBTCM GASKET
IMPORTANT: For gasket damages of 5/8 in. or larger, the EBTCM unit should be replaced. You will need to obtain LOCTITE 5900 to repair the damaged gasket.
1. Clean EBTCM surface area.
2. Locate damage(s) on gasket.
3. Clean and dry damaged area(s). Remove pieces of damaged gasket.
4. Cut tip of nozzle to desired opening. Gaskets are best formed using a 1/16 inch or 1/8 inch bead.
5. Carefully apply Loctite material evenly to damage area. Do not leave any gaps between gasket groove, original seal, and new material.
6. Fill gaps by smoothing out seal using a piece of plastic (or equivalent).
7. Once gasket has been repaired, join housing together and install screws. Remove excess material immediately.
Torque: 4 - 6 Nm (35 - 53 inch lbs.)
MID-RAIL BRACKET
NOTICE: Only the mid-rail bracket can be replaced separately. Bracket attached to the brake pressure modulator valve (BPMV) is only available when the BPMV is ordered. The BPMV bracket cannot be ordered separately.
REMOVAL
1. Remove bolts securing bracket to mid-rail.
INSTALLATION
2. Align bracket to mid-rail, then install and torque bolts.
Torque: 16 Nm (12 ft. lbs.)
INSTALLATION
1. Position ABS control assembly on mid-rail bracket by sliding towards rear of vehicle. Slide rearward to align bracket tab into bracket slot, then install and torque mid-rail bolt.
Torque: 12 Nm (106 inch lbs.)
2. Remove plugs from brake lines and install brake pipes to proper location on brake pressure modulator valve.
Torque: 26 Nm (19 ft. lbs.)
3. Install electronic brake and tractor control module electrical connector.
4. Connect electrical connector and push in tab to lock.
5. Connect brake fluid level switch electrical connector.
6. Place powertrain control module in carrier.
7. Connect body electrical connector.
8. Install and torque powertrain control module bolts.
Torque: 6 Nm (53 inch lbs.)
9. Install air induction cover and hose assembly.
10. Fill brake fluid reservoir to the base of reservoir filler neck with DOT 3 brake fluid.
11. Bleed ABS system using Scan tool, refer to "ABS Automated Brake Bleed". Service and Repair