Hydraulic Control Assembly - Antilock Brakes: Service and Repair

REMOVAL PROCEDURE

CAUTION: For safety reasons, the brake pressure modulator valve assembly must not be repaired, the complete unit must be replaced. With the exception of the EBTCM, no screws on the brake pressure modulator valve assembly may be loosened. If screws are loosened, it will not be possible to get the brake circuits leak-tight and personal injury may result.

NOTICE: The use of rubber hoses or parts other than those specified for the ABS may lead to functional problems requiring major overhaul.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.





1. Disconnect the negative battery cable.
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Powertrain Management - 4.0, 4.6L.
3. Reposition the PCM to create access to the BPMV.

IMPORTANT: Note the location of the brake pipes to use as an aid during installation.

NOTICE: Protect the vehicle exterior from brake fluid spills when removing the BPMV.

NOTICE: Excessive bending of brake pipes during BPMV removal or installation may cause permanent damage that will require replacement.





4. Remove the 6 brake pipe fittings.
5. Disconnect the EBTCM connector and BPMV motor ground cable.
6. Remove the 3 EBTCM/BPMV assembly bracket nuts.
7. Disconnect and reposition the 2 transmission cooler lines.
8. Remove the EBTCM/BPMV assembly from the vehicle.
9. Remove the front insulator and insulator mounting bolt.
10. Remove the four EBTCM to BPMV bolts.

CAUTION: Do not pry the EBTCM from the BPMV as damage to the seal may result.





11. Separate the EBTCM from the BPMV by gently pulling forward until separated. Be careful not to damage the seal.
12. Clean any brake fluid spillage from the BPMV.
13. Clean the seal and BPMV gasket surface with alcohol.

INSTALLATION PROCEDURE





1. Install the EBTCM to the BPMV.

NOTICE: Refer to Fastener Notice in Service Precautions.

2. Install the 4 EBTCM to BPMV bolts.

Tighten the 4 bolts to 5 Nm (40 inch lbs.).

3. Install the front insulator and insulator mounting bolt.

Tighten the insulator bolt to 14 Nm (10 ft. lbs.).

IMPORTANT: If a new BPMV is being installed, remove the shipping plugs from the valve openings.





4. Position the EBTCM/BPMV assembly in the bracket and install insulators and bracket nuts.
5. Install the EBTCM/BPMV assembly bracket nuts.

Tighten the bracket nuts to 10 Nm (89 inch lbs.).

CAUTION: Make sure brake pipes are correctly connected to BPMV. If brake pipes are switched by mistake (inlet vs. Outlet), wheel lockup will occur and personal injury may result.





6. Install the 6 brake pipe fittings, using locations noted during removal.

Tighten the 6 brake pipe fittings at the BPMV to 16 Nm (12 ft. lbs.).

7. Install the 2 transmission cooler lines.
8. Install the EBTCM connector. Make sure the EBTCM connector tab is locked down.
9. Install the pump motor ground cable connector.
10. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Powertrain Management - 4.0, 4.6L.
11. Install the negative battery cable.
12. Fill and bleed hydraulic brake system, Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
13. Perform the Auto Bleed Procedure. Refer to ABS Bleed Procedure.
14. Perform the ABS Diagnostic System Check. Refer to A Diagnostic System Check - ABS.