Hydraulic Control Assembly - Antilock Brakes: Service and Repair

ABS, ABS/EDL Hydraulic Unit, Vacuum Brake Booster And Brake Master Cylinder (Teves 04)

CAUTION: DO NOT separate the ABS hydraulic pump from the valve block.

NOTES: The illustration is an exploded view of the ABS/EDL unit. Servicing for ABS alone is identical.

1 Brake pedal position sensor -G1OO-
2 Spacer cap
3 0-ring
- Always replace
4 Circlip
- Always replace
5 Brake line
- Brake master cylinder (primary piston circuit) to ABS hydraulic unit -N55-
6 Vacuum brake booster
7 Bracket
8 Seal
9 Pin
10 Brake fluid reservoir
11 Cap
12 Clip
13 Screw
14 EDL series resistance -N159-
15 Self-locking nut
- 25 Nm (18 ft lb)
16 Brake master cylinder
17 Shield
18 Bolt
19 ABS hydraulic unit -N55-
20 ABS/EDL hydraulic unit -N55-
21 Brake line connection
- To right-front brake caliper
22 Torx� bolts
- T25
23 Brake line connection
- To left-rear brake caliper
24 Brake line connection
- To right-rear brake caliper
25 Brake line connection
- To left-front brake caliper
26 Brake line
- Brake master cylinder (secondary piston circuit) to ABS hydraulic unit -N55-

REMOVING

NOTE: For easier removal and installation, removing the complete ABS hydraulic unit with vacuum brake booster and brake master cylinder is recommended.

- Disconnect battery Ground (GND) strap.
- Disconnect all electrical connections from ABS hydraulic unit -N55-.
- Remove brake fluid from reservoir.
- Disconnect brake lines from ABS hydraulic unit -N55- and seal threaded holes with plugs.
- Remove shelf below left-side instrument panel.
- Disconnect brake pedal from vacuum brake booster.
- Remove nuts securing vacuum brake booster to bulkhead.
- Remove ABS hydraulic unit, with brake master cylinder and vacuum brake booster, from engine compartment.

INSTALLING

NOTE: ABS hydraulic units supplied as replacement parts are filled with hydraulic fluid and bled.

CAUTION: Remove sealing plugs one at a time, only when the particular brake line is going to be connected. Otherwise, brake fluid may escape and the unit may no longer be sufficiently filled or adequately bled.

- Pre-assemble ABS hydraulic unit -N55-, brake master cylinder and vacuum brake booster away from vehicle.
- Install ABS hydraulic unit, vacuum brake booster and master cylinder.
- Install brake lines.
Reconnect electrical harness connectors to ABS hydraulic unit.
- Bleed brake system.
- Install shelf below instrument panel on left-side.

Tightening Torques:
- Brake booster to bulkhead: 25 Nm (18 ft lb)
- Brake lines to ABS unit, M1O: 15 Nm (11 ft lb)
- Brake lines to ABS unit, M12: 15 Nm (11 ft lb)