Without Traction Control

Brake Control Modulator

Special Service Tool

Brake Pedal Hold Tool

Removal

CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. Remove brake fluid spillage immediately from paint work, with clean water.

1. Disconnect battery ground cable.

2. Position vehicle on a four-post lift.

3. Open engine compartment and fit paint work protection covers to fenders.

NOTE: The following three pictorial procedures must be carried-out to minimize brake fluid loss when disconnecting the brake tubes.





4. Open Left-Hand-Front and Left-Hand-Rear caliper bleed nipples.
- Connect a bleed tube and container to the calipers.
- Open bleed nipples.





5. Depress and hold down brake pedal to the specified position using special tool.
- Position tool between brake pedal and seat frame.
- Turn the tool wheel until the brake pedal is held 60 mm down from its released position.





6. Tighten bleed nipples to:
- Front caliper bleed nipple 4 - 6 Nm.
- Rear caliper bleed nipple 8 - 11 Nm.
- Remove bleed tubes and containers.





7. Disconnect the upper electrical connector.
- Pull plunger upwards.
- Release connector.

8. Position an absorbent cloth underneath the brake control modulator to collect brake fluid spillage.

CAUTION: Remove brake fluid spillage immediately from paint work, with clean water.

NOTE: To minimize brake fluid loss, release the brake tubes in the order shown.





9. Release brake tubes.
- Undo union nuts and release inlet brake tubes.
- Install plugs to inlet ports and brake tubes.
- Undo union nuts and release outlet brake tubes.
- Install plugs to outlet ports and brake tubes.





10. Remove brake control modulator from bracket.
- Remove bolts.

11. Clean components and mating surfaces.

Installation

NOTE: The replacement brake control modulator is pre-filled with brake fluid.





1. Install brake control modulator to bracket.
- Install bolts and tighten to 8 - 10 Nm.

NOTE: To minimize brake fluid loss, install the brake tubes in the order shown.





2. Install brake tubes.
- Remove plugs from outlet ports and brake tubes.
- Install and tighten outlet brake-tube union nuts.
- Remove plugs from inlet ports and brake tubes.
- Install and tighten inlet brake-tube union nuts.





3. Connect upper electrical connector.
- Push plunger down to secure connector.

4. Remove special tool from brake pedal.

5. Reconnect battery ground cable.

6. Bleed brake system.