Brake Pipe Master Cylinder / ABS Unit, Replacing

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 in this section show the left-hand drive version.

Preparation

Disconnect the battery lead
See Battery, disconnecting Battery Disconnecting

Removing pipes

Collect the brake fluid
See

Remove the plastic cap and the cable holder




Switch off the ignition.

Remove:
- the plastic cap over the positive cable
- the positive cable nut at the wheel arch. Fold the cable to one side
- the screw on the clamp around the positive cable
- the nuts on the cable holder.

Remove the air cleaner (ACL) housing




Pull the air intake backwards (towards the engine) so that it disconnects from its mounting under the front cover plate.
Disconnect the hose clamp for the air hose.
Remove all the air hoses and connectors from the air cleaner (ACL).
Remove the air cleaner (ACL) housing from its mountings. Pull it straight up.

Remove the integrated relay / fusebox




Remove the integrated relay / fuse box bracket screw. Lift it up and put to one side. Tie it up using a cable.

Remove the brake pipes between the master cylinder and the ABS unit




Clean the brake pipes terminals 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 sealing plugs.
Remove the brake pipes.

Installing pipes

Install the brake pipes




Tighten the pipes to 17 Nm .

Install the integrated relay / fusebox





Install:
- the bracket and the integrated relay / fusebox in the mounting
- screw in the bracket. Tighten to 10 Nm .

Install the cable holder and plastic cap





Install:
- the cable holder. Tighten the nuts, Tighten to 10 Nm
- the positive cable and integrated relay / fusebox nut. Tighten to 25 Nm
- the screw on the clamp around the positive cable
- the plastic cap at the positive cable.

Install the air cleaner (ACL) housing




Connect all the air hoses and connectors to the air cleaner (ACL) housing.
Tighten the hose clamp.
Fold the air intake in under the front cover plate.
Locate it in its mounting and press it into place.
The positioning of the air intake can be seen through an oblong hole in the front cover plate.

Fill and bleed the brake system
Remove the pedal jack.
Fill and bleed the brake system.

Checking for air in the brake system and for brake fluid leakage




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 re-check the pedal travel.
Check that no leakage occurs from the brake nipples, hoses and joints.
Remove the bleed unit connector from the brake fluid reservoir.
Check that the brake fluid level is not above maximum.