Brake Pipe Replacement (Master Cylinder to ABS Controller)

Brake Pipe Replacement (Master Cylinder to ABS Controller)

Removal Procedure

Caution: Refer to Battery Disconnect Caution (Battery Disconnect Caution) .
1. Disconnect the battery.




2. Remove the battery shield (2).

* Remove the bolt (3).
* Disconnect the 2 shields (1) from the battery carrier.





3. Remove the battery holder (1).
Remove the bolt.
4. Remove the battery.
5. Remove the coolant compensation tank from mounting and set aside.
Disconnect the wiring harness plug for coolant level sensor.




6. Remove cover of brake fluid reservoir.
7. Siphon out as much of the brake fluid as possible with a siphon bottle.
8. Disconnect the brake line for brake master cylinder circuit 1 from hydraulic modulator (2) first, then from the brake master cylinder (1).

Important: Seal off the open brake line connections on the hydraulic modulator and brake master cylinder from contamination using plugs.


9. Disconnect the brake line for brake master cylinder circuit 2 from hydraulic modulator (3), then from the brake master cylinder (4).



Installation Procedure

1. Position the brake line for the brake master cylinder circuit 2 (1) on hydraulic modulator and on brake master cylinder.
Hand tighten both unions.

Important: Align both brake lines in such a way that they do not touch each other, even in the flexible section, and run parallel to each other.


2. Position the brake line for the brake master cylinder circuit 1 (2) on hydraulic modulator and on brake master cylinder .
Hand tighten both unions.

Notice: Refer to Fastener Notice (Fastener Notice) .

3. Install the 4 brake lines to hydraulic modulator and brake master cylinder.

Tighten brake lines to hydraulic modulator and brake master cylinder to 14 N.m (124 lb in).

4. Connect the coolant compensation tank to mounting.
5. Install the battery.
6. Install the battery shield.
Install the 2 shields, battery tray .

Tighten the battery shield bolt to 10 N.m (89 lb in).

7. Install the battery holder.

Tighten the battery holder bolt to 7 N.m (62 lb in).

8. Connect the battery.
9. Connect the positive cable.
10. Connect the ground cable.

Important: If the brake pedal is not hard, refer to Antilock Brake System Automated Bleed Procedure (Service and Repair) .


11. Bleed the brake system. Refer to Hydraulic Brake System Bleeding (Service and Repair) .
12. Top up brake fluid to the "MAX" mark.
13. Install the cover onto the brake fluid reservoir.