Section C - ABS Hydraulic Modulator Replacement
BEGIN SECTION "C" ABS Hydraulic Modulator ReplacementSection "C" will be completed when any of the ABS Hydraulic Modulator valves fail the inspection in section "A". In this case the ABS Hydraulic Modulator will be replaced. The new modulator will come with the required brake fluid, therefore the brake cycling procedure is not needed. Section "B" will not be necessary in this case.
WARNING
Brake fluid may irritate eyes and skin.
In case of contact, take the following actions:
^ Eye contact: rinse thoroughly with water.
^ Skin contact: wash with soap and water.
^ If ingested: consult a physician immediately.
WARNING
Engine coolant can burn you when hot.
To prevent personal injury, do not attempt to remove the surge tank cap or hoses while the engine and the radiator are hot, as hot fluid and steam may be blown out when under pressure.
NOTE:
Contact ASMC Techline and request release of 1 ABS Hydraulic Modulator part number 56100-85Z20. An SR file will be opened and the part will be sent for overnight delivery.
Removal Procedure
1. Turn the ignition switch to the OFF position.
2. Drain all the brake fluid from the complete brake system.
3. Drain the engine coolant to below the level of the surge tank.
4. Loosen the return hose clamp and disconnect the return hose from the top of the surge tank.
5. Loosen the throttle body hose clamp and disconnect the throttle body hose from the surge tank.
6. Loosen the feed hose clamp and disconnect the feed hose from the bottom of the surge tank.
7. Remove the surge tank attaching bolts.
8. Remove the surge tank.
9. Clean the ABS modulator assembly pipe fitting areas of any accumulated dirt and foreign material.
10. Disconnect the electrical connector from the electronic brake control module (EBCM).
11. Place shop towels under the ABS modulator assembly to catch any brake fluid loss. Be sure to protect the electrical connector and socket from any contact with brake fluid. Always use fender covers or adequate covers and protection over the vehicle fenders to protect the paint finish.
NOTE:
Prior to disconnecting the brake pipes from the ABS Hydraulic Modulator assembly, note the locations of the brake pipes to the valve assembly, to aid during installation.
12. Disconnect the brake pipe fitting nuts from the ABS Hydraulic Modulator.
13. Cap the brake pipe ends to prevent contamination.
14. Plug the ABS Hydraulic Modulator brake pipe openings to prevent brake fluid loss and contamination.
15. Remove the mounting bracket fasteners from the vehicle body panel and remove the ABS module from the vehicle.
16. Remove the ABS modulator assembly bracket bolt, then remove the ABS module from the bracket by sliding it out from the two damping grommets.
17. Remove the two mounting pins (# 1) from the ABS Hydraulic Modulator.
18. Remove the three fasteners (# 2) holding the EBCM to the hydraulic module.
19. Slide the EBCM from the hydraulic module.
Install the new ABS Hydraulic Module in reverse order.
1. Slide the EBCM onto the ABS Hydraulic Module and tighten the three fasteners.
a. (Torque 1.8 Nm (16 lb-in))
2. Install the two mounting pins to the ABS Hydraulic Modulator.
a. (Torque 8 Nm (6 lb-ft))
3. Install the ABS modulator assembly to the modulator bracket by seating the pins into the dampers and installing the single bracket bolt.
a. (Torque 11 Nm (8 lb-ft))
4. Install the ABS modulator assembly with the mounting bracket attached to the vehicle's body panel.
a. (Torque 22 Nm (16 lb-ft))
5. Remove the caps from the brake pipe ends.
6. Remove the plugs from the brake pipe ports on the ABS Hydraulic Modulator assembly.
7. Connect the brake pipes to the ABS Hydraulic Modulator in the same positions noted when removed. Tighten each brake pipe fitting.
a. (Torque 16 Nm (12 lb-ft))
8. Connect the electrical connector to the EBCM.
9. Install the engine coolant reservoir tank.
10. Fill the coolant reservoir and adjust the cooling system fluid level.
11. Fill the brake system with only Suzuki approved brake fluid, part number 990B0-99900-PKG brake fluid.
12. Perform brake bleeding procedure to the complete brake system. See Section "D".
13. Perform the ABS Hydraulic Module Inspection once again to confirm the module is operating correctly.
NOTE:
This step is only to confirm the module is operating correctly. If the test passed all 4 cycles, no further action is needed. If any of the four cycles fail, please contact Tech Line for direction.
14. Confirm Section "D" - Brake System Bleeding Procedure, has been completed prior to campaign completion and label installation.
15. This recall campaign is complete. Apply the proper campaign label to the upper radiator support in an area where it will be easily seen and identified, and write your dealer code in the white portion of the label. Perform a road test to confirm proper brake operation and return the vehicle to the owner.
END OF SECTION "C"
- ASB Modulator Replacement