Brake Pressure Modulator Valve Replacement

Brake Pressure Modulator Valve Replacement

Removal Procedure


Important: It is essential to comply with the instructions for the hydraulic modulator and the ABS control unit. Refer to ABS Control Unit General Repair Specification (ABS Control Unit General Repair Specification) .


1. Remove the cover of the brake fluid reservoir.
2. Siphon out as much brake fluid as possible with a siphon bottle.
3. Remove the battery.

* Remove the ground connection from the ground terminal.
Release the nut.
* Remove the positive connection from the battery.
Remove the nut.
* If present, remove the thermal protection.
* Remove the bracket.
Remove the bolt.
* Remove the battery.





4. Remove the battery support.

* For diesel engines, remove the preheater system control unit (4).
* Remove the wiring harness plug (3).
* Remove the coolant hose.
* Release the clip (5).
* Remove the wiring harness.
Disconnect the 2 cable ties (1).
* Remove the 3 bolts (2).
* Remove the hydraulic modulator.


Important: Cooling system remains sealed.


5. Remove the coolant surge tank.
Disconnect the wiring harness plug.
Set the coolant surge tank aside.




6. Remove the hydraulic modulator.

* Disconnect the hydraulic modulator wiring harness plug.
* Remove the 6 hydraulic lines (2).
* Install the 6 sealing plugs on the hydraulic modulator.
* Remove the 3 bolts (1).




Installation Procedure


Notice: Refer to Fastener Notice (Fastener Notice) .

1. Install the hydraulic modulator.

Tighten the 3 hydraulic modulator bolts to 8 N.m (71 lb in).


* Remove the 6 sealing plugs from the hydraulic modulator.
* Install the 6 hydraulic lines.

Tighten the 6 hydraulic lines retaining bolts to 14 N.m (124 lb in).

* Connect the hydraulic modulator wiring harness plug.

2. Install the coolant surge tank to the mounting.
Connect the wiring harness plug for the coolant level sensor.
3. Install the battery support.

Tighten the 3 battery support bolts to 10 N.m (89 lb in).


* For diesel engines, install the preheater system control unit.
* Install the wiring harness plug.
* Install the coolant hose.
* Install the wiring harness.
Install the 2 cable ties.

4. Install the battery.

* Install the battery bracket.

Tighten the battery bracket bolt to 15 N.m (11 lb ft).

* If present, install the thermal protection.
* Install the battery positive connection to the positive terminal.

Tighten the battery positive connection nut to 5 N.m (44 lb in).

* Install the battery ground connection to the ground terminal.

Tighten the battery ground connection nut to 5 N.m (44 lb in).


5. Bleed the brake system. Refer to Hydraulic Brake System Bleeding (Service and Repair) .
6. Top up the brake fluid reservoir to the MAX marking.
7. Install the cover onto the brake fluid reservoir.
8. For programming procedures, refer to Control Module References (Programming and Relearning) .