Brake Pipe Master Cylinder / ABS Unit

Brake pipe master cylinder/ABS unit, replacing

Note: The method is almost the same for left and right-hand drive versions. On right-hand drive cars, the brake pipes are positioned between the master cylinder and the ABS unit. They are clamped to the cowl in two places. All the illustrations show the left-hand drive version.

Preparation
Switch off the ignition
Disconnect the battery lead. VCC-104452

Removal
Collect the brake fluid. Replacing the front brake calipers

Removing the air cleaner (ACL) housing





Remove the Air Cleaner (ACL) housing and the intake manifold assembly.

Removing the integrated relay /fusebox





- remove the nut for the positive cables
- lift the cable terminals away from the screw
- remove both the screws.





- remove the integrated relay/fusebox from the bracket
- lift up the front edge of the box (1). Press the box (2) to the side. Then angle the box out of the bracket (3).

Removing the brake pipes between the master cylinder and ABS unit





- Clean the terminals for the brake pipes at the master cylinder and ABS unit
- Place paper under the master cylinder to avoid brake fluid spillage
- Remove the brake pipes from the master cylinder and ABS unit. Install plugs.

Installation

Installing the brake pipes





Tighten the brake pipes. Tighten to 17 Nm.

Installing the integrated relay/fusebox on the bracket





- Align the box (1) in the bracket (2). Push the box to the side. Release the box so that it aligns in the bracket (3)
- Tighten the screws. Tighten to 10 Nm
- Reinstall the positive cables and the nut for the relay box. Tighten to 25 Nm.

Installing the air cleaner (ACL) housing





- Connect all air hoses and the connector to the Air Cleaner (ACL) housing
- Tighten the hose clamps.

Bleeding the brake system
Remove the pedal jack.
Fill and bleed the brake system. Brake system, bleeding (using bleeding unit)

Brake system, bleeding

Checking for air in the system.

Checking for brake fluid leaks





Check if there is still air in the system. Press down the brake pedal using a jack at a pressure equivalent to heavy braking 200 Nm. With the engine off and the brake pedal depressed 3-4 times, the pedal travel must not exceed 40 mm.
If the pedal travel exceeds this limit, bleed again and recheck the pedal travel.
That there is no brake fluid leakage.
Remove the bleed unit connector from the brake fluid reservoir.
Check that the brake fluid level is not above the maximum marking.