Brake Pressure Modulator Valve (BPMV) Replacement
REMOVAL PROCEDURECAUTION: 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.
BPMV Assembly (With TCS):
1. Disconnect the negative battery cable.
2. Remove the air cleaner assembly.
3. Disconnect the following electrical connectors from the BPMV:
^ The fluid level switch connector
^ The pump motor connector
^ The valve block connector
4. Remove the clamp that is on the reservoir hose to BPMV reservoir.
5. Obtain a 15.5 mm (5/8 inch) plug to be used in the next step.
6. Remove the reservoir hose from the BPMV reservoir.
7. Remove the primary brake pipe from the BPMV.
8. Remove the secondary brake pipe from the BPMV.
9. Raise and suitably support the vehicle.
10. Remove the left front wheel splash shield.
11. Remove the brake pipes from the BPMV.
12. Remove the BPMV to bracket bolts.
13. Remove the BPMV from the bracket. Set the BPMV aside.
14. Remove the BPMV bracket.
15. Remove the BPMV from the vehicle through the left front wheel well.
16. Transfer the necessary parts to the new BPMV unit.
INSTALLATION PROCEDURE
IMPORTANT: Improper installation or inversion of the metal gasket may introduce extremely high pressures during the autobleed procedure. This high pressure may cause severe damage to various components on the brake system.
Ensure that the locator tab position is correct so that none of the internal ports between the pump and the valve block assembly are blocked.
NOTICE: Refer to Fastener Notice in Service Precautions.
1. Install the BPMV valve block to pump bolts.
^ Tighten the BPMV valve block to pump bolts to 29 Nm (21.4 ft. lbs.).
2. Install the BPMV into the vehicle.
3. Set the BPMV to the side.
4. Install the BPMV bracket.
5. Install the BPMV to bracket bolts.
^ Tighten the bolts to 27 Nm (20 ft. lbs.).
BPMV Assembly (With TCS):
6. Install the brake pipes to the BPMV.
^ Tighten the brake pipes to 15 Nm (11 ft. lbs.).
7. Install the primary brake pipes to the BPMV.
8. Install the secondary brake pipes to the BPMV.
^ Tighten the brake pipes to 15 Nm (11 ft. lbs.).
9. Connect the reservoir hose to the BPMV reservoir.
10. Install the reservoir clamp.
11. Install the following electrical connectors to the BPMV:
^ The fluid level switch connector
^ The pump motor connector
^ The valve block connector
12. Connect the negative battery cable.
^ Tighten the battery cable to 15 Nm (11 ft. lbs.).
13. Install the left front splash shield.
14. Install the air cleaner assembly.
15. Fill the brake fluid reservoir.
16. Bleed the brake system.
17. Clean the brake fluid from the BPMV area in order to prevent damage to the vehicle components.
18. Perform the ABS Diagnostic System Check. Refer to ABS Diagnostic System Check.
Testing BPMV For Internal Leaks
If internal leakage of the brake system is a reoccurring problem, perform the following test first in order to verify if the BPMV is malfunctioning or not.
1. Remove the low pressure return hose at the BPMV reservoir.
2. With the ignition switch in the RUN position, have an assistant gently apply pressure to the brake pedal three to five times.
3. Inspect the BPMV reservoir Outlet for fluid leaking out when pressure is applied to the brake system. If fluid leaks from the BPMV outlet, the BPMV is malfunctioning and should be replaced.