Brake Pipe, Junction/ABS Unit, Replacing

Brake pipe junction/ABS unit, replacing

Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Preparatory work

Disconnect the battery lead. See Battery, disconnecting Battery Disconnecting.




Secure the pedal in the depressed position. Use a pedal jack.
Remove the protective cap from the bleed nipple at the left front wheel.
Install a plastic hose on the nipple. Open the bleed nipple. Collect the brake fluid in a container.
Shut the bleed nipple.

Removal

Removing the air cleaner (ACL) housing




Disconnect the hose clamp for the air hose.
Remove all the air hoses and connectors from the air cleaner (ACL) housing.
Remove the air cleaner (ACL) housing from its mountings. Pull it straight up.

Removing the integrated relay / fusebox





Remove:
- the nut for the power cables
- the 2 power cables
- the 2 screws for the mounting.




Open the integrated relay/fusebox. Remove the connector (1).
Disconnect the cable harness from the box (2).
Lift the box out of the mounting and move it to one side.

Removing the brake pipe junction / ABS unit




Clean around the brake pipe on the ABS hydraulic modulator. Remove the brake pipe from the ABS hydraulic modulator and holder.




Straighten the brake pipe by the ABS hydraulic modulator.
Raise the car.

Remove:
- the left front wheel
- the screw for the bracket for the brake pipe and brake hose
- the holder from the brake pipes.
Clean the brake pipe and joint nipple.
Separate the brake pipe at the joint nipple.
Remove the brake pipe from its clips.

Note! Cut the brake pipe at the bracket. Leave the pipe that has been cut in place as a guide for installation of the new brake pipe.

Installation

Installing the brake pipe junction / ABS unit

Note! For tightening torques, see: Tightening torque [1][2]Specifications.

Note! The new brake pipe must be bent into the correct shape when installing. This is important otherwise the pipe may be subject to stresses when it is in place.

Remove the cut-off brake pipe. Install the new one.
Tighten the brake pipe in the joint nipple. Tighten. See: Tightening torque [1][2]Specifications.
Secure the brake pipe in its clips in the body floor.
Bend and adjust the brake pipe so that it aligns with the hydraulic unit.





Install:
- the brake pipe in the ABS hydraulic modulator. Tighten. See: Tightening torque [1][2]Specifications
- the brake pipe in its clips at the bracket. Adjust the pipe as necessary
- the clip holder on the brake pipes by the side member
- the bracket. Tighten. See: Tightening torque [1][2]Specifications.

Note! The brake pipes must not be in contact with each other or the car body.

Installing the integrated relay / fusebox
Install the box in its mounting.

Install:
- the cable harness
- the connector
- the 2 x M6 screws in the mounting
- the 2 x power cables
- the M8 nut to secure the power cables.

Installing the air cleaner (ACL) housing
Press the air cleaner (ACL) housing into place.
Install the air hoses and the connector.

Finishing

Bleed the brake system. See Brake system, bleeding (using bleeding unit) Bleeding Brakes With A Bleeding Unit.
Connect the battery lead.

Testing the pressure of the brake system




Depress the brake pedal hard for 30 seconds. Check that no leakage occurs from the brake nipples, hoses and joints.
Remedy any leakage.
Install the wheel. See Installing wheels Service and Repair.