Hydraulic Control Assembly - Antilock Brakes: Service and Repair

Early Production

Hydraulic Assembly:

REMOVAL
1. Depressurize hydraulic accumulator as outlined under MAINTENANCE PROCEDURES.
WARNING: Failure to depressurize hydraulic accumulator, prior to performing this operation, may result in personal injury and/or damage to painted surfaces.
2. Disconnect all electrical connectors from hydraulic assembly.
3. Using a screwdriver, remove the retaining clip at the brake pedal pin under the instrument panel. Discard the retainer clip.
4. Remove driver's side sound insulator panel, then the four hydraulic assembly mounting nuts.
5. From under the hood, remove hydraulic assembly enough to gain access to the sensor block cover.
NOTE: Brake lines should not be removed or deformed during this procedure.
6. Remove sensor block cover retaining bolt and remove sensor block cover taking care not to damage the gasket.
7. Using fingers or a small screwdriver, disengage the locking tabs and disconnect the valve block connector (12-pin) from the sensor block.
8. Disengage the reed block connector (marked "PUSH") by carefully pulling outward on the orange connector body. The connector is partially retained by a plastic clip and will only move outward approximately 1/2 inch (13 mm).
9. Remove the three sensor block retaining bolts.
10. Carefully, disengage the sensor block pressure port from the hydraulic assembly and remove the sensor block from car. The sensor block pressure port is sealed with an O-ring and extra care should be taken to prevent damage to the seal.

INSPECTION
Inspect O-rings and sensor block. Replace O-ring if cut or damaged. Inspect sensor block wiring for any misrouting or damage. Correct any damage or replace sensor block if damage cannot be corrected.

INSTALLATION
1. Pull reed block connector (2-pin) outward to its disengaged position.
2. Lubricate the sensor block pressure port O-ring with clean brake fluid then carefully insert pressure port into hydraulic assemblies orifice, taking care not to cut or damage the O-ring.
3. Position sensor block, then install sensor block mounting bolts. Tighten to 15 N-m (11 lb-ft).
4. Engage reed block connector by pressing on orange connector body marked "PUSH."
5. Connect valve block connector (12-pin) to sensor block.
6. Install sensor block cover, gasket, and mounting bolt.
7. Connect sensor block and control pressure switch connectors.
8. Reinstall hydraulic assembly, following reverse order of removal.