Removal and Installation

WARNING: To help avoid personal injury due to the retained load on the hydraulic modulator/motor pack assembly, perform the gear tension relief function of the scan tool before removing the hydraulic modulator/motor pack assembly.

Removal Procedure
1. Using the scan tool, perform the gear tension relief sequence. Gear Tension Relief Sequence
2. Disconnect the negative battery cable.
3. Remove the bolt securing the surge tank.





4. Slide the surge tank off its mount at the end opposite the bolt.
5. Move the surge tank out of the way to access the hydraulic modulator.





6. Disconnect the ABS solenoid connectors.
7. Disconnect the motor pack electrical connector.
8. Place a shop cloth beneath the hydraulic modulator brake pipes to prevent brake fluid from contaminating the motor pack or the electrical connectors.





9. Disconnect the six brake pipes from the hydraulic modulator.
9.1 Plug the brake pipes to prevent loss or contamination of brake fluid.
10. Remove the bolt at the front of the base of the hydraulic modulator/motor pack assembly.
11. Remove the hydraulic modulator/motor pack assembly from the vehicle.
12. Rotate the front end of the hydraulic modulator/motor pack assembly toward the engine while pulling the back end away from the fire wall to get the mounting foot out from under the loop in its mounting bracket.

Installation Procedure





1. Install the hydraulic modulator/motor pack assembly to the vehicle.
Tighten
Tighten the hydraulic modulator/motor pack assembly bolt to 5.4 Nm (48 inch lbs.).
2. Remove the plugs from the brake pipes and connect them to the hydraulic modulator. Secure each pipe with a pipe nut.
Tighten
Tighten the brake pipe nuts to 15 Nm (11 ft. lbs.).





3. Install the motor pack and solenoid electrical connectors.

Important: Make sure the solenoid electrical connectors are correctly installed. The white connector goes to the solenoid at the front end of the hydraulic modulator and the black connector goes to the solenoid toward the fire wall.





4. Replace the surge tank in its mounting and secure it with the bolt.
Tighten
Tighten the surge tank mounting bolt to 8 Nm (71 inch lbs.).
5. Connect the negative battery cable.
6. Bleed the brake system. Brake Bleeding
7. Check the engine coolant level (ECL), add a 50-50 mixture of antifreeze and water, if necessary.