Brake Pipe Master Cylinder/ABS Unit, Replacing

Brake pipe master cylinder/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.

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

Removing the upper torque rod





Remove:
- the mounting screws for the torque rod
- the screw and nut for the engine mounting and torque rod
- the engine stabilizer brace.

Removing the air cleaner (ACL) housing




Remove the screws (1) for the intake manifold.
Disconnect the hose clamp (2) for the air hose.
Remove the connector (3) from the mass air flow (MAF) sensor.
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 pipes between the master cylinder and 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.

Installation

Installing the brake pipes

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.

Install the brake pipes. Tighten. See: Tightening torque [1][2]Specifications.

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

Install:
- the cable harness
- the connector
- the 2 x M6 screws for 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.

Installing the upper torque rod

Install:
- the engine stabilizer brace
- the M12 screw and nut for the engine mounting
- the 4 x M10 mounting screws for the torque rod.

Finishing




Bleed the brake system. See Brake system, bleeding (using bleeding unit) Bleeding Brakes With A Bleeding Unit.
Check if there is still air in the system by pressing down the brake pedal with 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.
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.
Connect the battery lead.