Note: If any ABS component is defective, the entire hydraulic modulator assembly must be replaced. excluding relay box (paragraph 22) Spare parts for this system are not supplied.
1. On models manufactured before 1997, a Mecatronic hydraulic modulator is installed, on models manufactured since 1997, a Bosh 5.3 hydraulic modulator is installed. Mecatronic hydraulic modulators are divided depending on the time of their release into two types: early and late release. The removal and installation procedures for all hydraulic modulators have much in common.
Removal - Early Mecatronic Hydraulic Modulators
2. Relieve both pressures (paragraph 19).
Models with V-shaped 6-cylinder engines
3. Remove the bottom panel of facing from the front panel from the driver's side. Then, in the driver's footwell, unscrew the nuts securing the pedal box assembly and lower this assembly as low as possible.
4. On models with an air conditioning system, contact your dealer to depressurize the system and remove the refrigerant. Disconnect the pipelines (of necessity) from the hydromodulator installation area. Warning: do not disconnect the piping of the air conditioning system if this system is charged with refrigerant (chapter 3 paragraph 12).
5. Remove the bolts and remove the brake booster brackets from the engine compartment.
Right hand drive models
6. Have an assistant depress and hold the brake pedal. Pull out the elastic retainer and remove the pin that secures the servo booster pusher to the pedal connecting rod.
7. Remove the vacuum booster and remove it from the engine compartment.
Left hand drive models
8. Turn away a nut of fastening of a pin of a pedal to a pusher of the servo amplifier from inside salon. The nut is located near the top of the pedal and can be unscrewed through the access hole. To improve access, first remove the lower part of the cladding from the front panel.
9. Remove the vacuum booster together with the pusher and remove this assembly from the engine compartment. Be careful not to damage the rubber bushing in the baffle.
All models
10. Disconnect the remaining brake lines from the ABS hydraulic modulator. To do this, unscrew the connection nuts and pull out the pipes. Slightly bend the pipes away from the hydraulic modulator so that it can be removed.
11. Disconnect the hydromodulator electrical connectors. To disconnect the main 22-pin electrical connector, press the lock, tilt the connector plug and pull it out.
12. Turn away a fixing nut of the pump and nuts of fastening of a hydromodulator.
13. Raise the ABS hydraulic modulator from its left side, and then tilt the shaft assembly. so that he comes out of the right support. Be careful not to lose the bracket studs and insulator ring.
Installation - Early Mecatronic Hydro Modulators
14. Install the insulator ring on the end of the pump and place the cap on the insulator ring.
15. Install the hydraulic modulator in its place (right side first).
16. Install the right bracket studs on the insulators..
17. Lower the hydraulic modulator with the left side onto the bracket. Then install and tighten the pump fixing nut.
Left hand drive models
18. Install the vacuum booster and pusher on the baffle bracket taking care not to damage the rubber bushing.
19. Insert a pusher into a pin of a pedal and tighten a nut.
20. Install the lower bezel trim if removed.
Right hand drive models
21. Install the vacuum booster and pusher on the baffle bracket.
22. Install the servo pusher pin and retainer to the pedal link rod.
All models
23. Connect the electrical connectors to the hydraulic modulator. Attach the brake lines to the hydraulic modulator and tighten the nuts. Install both pressure relief valves (paragraph 20). On models with V-shaped 6-cylinder engines, restore the connections of the pipelines of the air conditioning system and pump refrigerant into it.
Removal - Late Mecatronic Hydraulic Modulators
24. Disconnect the negative battery cable (chapter 5A).
25. Remove the air cleaner and intake duct (chapter 4A). On models with 4-cylinder engines, remove the intake air duct chamber.
26. Disconnect the electrical connector of the fluid level sensor in the reserve tank of the hydraulic brake system. Disconnect the clutch fluid supply hose from its bracket. Move the hose to the side without disconnecting it (if possible).
27. Turn away and remove a cover of a reserve tank of a hydrosystem of brakes. Cover the reservoir neck with plastic wrap and secure it with duct tape to minimize leaks when disconnecting piping.
28. Turn away nuts of fastening of the main cylinder and accurately remove the cylinder from the vacuum servo booster, without disconnecting brake pipelines. Move the master cylinder to the left so that it rests on the top of the left suspension strut.
29. Turn away nuts of a servo amplifier and remove it from a partition.
Right hand drive models
30. Ask the assistant to press the brake pedal and hold it. Pull out the elastic retainer and remove the pin that secures the servo booster pusher to the pedal connecting rod.
31. Remove the vacuum booster and remove it from the engine compartment.
Left hand drive models
32. Turn away a nut of fastening of a pin of a pedal to a pusher of the servo amplifier from inside salon. The nut is located near the top of the pedal and can be unscrewed through the access hole. To improve access, first remove the lower part of the lining from the front panel, disconnecting the electrical diagnostic connector.
33. Remove the vacuum booster together with the pusher and remove this assembly from the engine compartment. Be careful not to damage the rubber bushing in the baffle.
All models
34. Disconnect the hydraulic modulator electrical connector.
35. Place rags under the hydraulic modulator to catch smudges.
36. Disconnect the remaining brake lines from the ABS hydraulic modulator. To do this, unscrew the connection nuts and pull out the pipes. Slightly bend the pipes away from the hydraulic modulator so that it can be removed.
37. Turn out 4 bolts of fastening of an arm of the hydromodulator and remove it together with arms.
Installation - Late Mecatronic Hydro Modulators
38. Installation - in the reverse order of removal. Restore the connections of the electrical connectors and pipes, tightening the fasteners to the required torque.
Removal - Bosh hydraulic modulators
39. Disconnect the negative battery cable (chapter 5A).
40. Remove the air cleaner and intake duct (chapter 4A). On models with 4-cylinder engines, remove the intake air duct chamber. Remove the air cleaner bracket.
41. Disconnect the electrical connector of the fluid level sensor on the reserve tank of the hydraulic brake system. Disconnect the clutch fluid supply hose from its bracket. Move the hose to the side without disconnecting it (if possible).
42. Turn away and remove a cover of a reserve tank of a hydrosystem of brakes. Cover the reservoir neck with plastic wrap and secure it with duct tape to minimize leaks when disconnecting piping.
43. Turn away nuts of fastening of the main cylinder and accurately remove the cylinder from the vacuum servo booster, without disconnecting brake pipelines. Move the master cylinder to the left so that it rests on the top of the left suspension strut.
44. Turn away nuts of a servo amplifier and remove it from a partition.
Right hand drive models
45. Ask an assistant to press the brake pedal and hold it. Pull out the elastic retainer and remove the pin that secures the servo booster pusher to the pedal connecting rod.
46. Remove the vacuum booster and remove it from the engine compartment.
Left hand drive models
47. Turn away a nut of fastening of a pin of a pedal to a pusher of the servo amplifier from inside salon. The nut is located near the top of the pedal and can be unscrewed through the access hole. To improve access, first remove the lower part of the lining from the front panel, disconnecting the electrical diagnostic connector.
48. Remove the vacuum booster together with the pusher and remove this assembly from the engine compartment. Be careful not to damage the rubber bushing in the baffle.
49. Turn away nuts of fastening of an arm of the servo amplifier located around a steering column on its basis. Remove the bracket from the bulkhead.
50. On models with an air conditioning system, move the air conditioning pipe bracket to the side.
51. Remove the bolts and brackets from the sides of the servo amplifier.
All models
52. Disconnect the hydraulic modulator electrical connector.
53. Place rags under the hydraulic modulator to catch smudges.
54. Disconnect the remaining brake lines from the ABS hydraulic modulator. To do this, unscrew the connection nuts and pull out the pipes. Slightly bend the pipes away from the hydraulic modulator so that it can be removed.
55. On models with V-shaped 6-cylinder engines, unscrew the 4 bolts securing the ABS assembly brackets and slide this assembly along with the brackets forward.
56. Turn away 2 nuts and pull out the hydromodulator from an adjusting ledge and brackets.
Installation - Bosh hydraulic modulators
57. Installation - in the reverse order of removal. Restore the connections of the electrical connectors and pipes, tightening the fasteners to the required torque.
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