GM Cavalier/Sunfire 1995-2000 Repair Guide

ABS Hydraulic Modulator/Master Cylinder Assembly

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REMOVAL & INSTALLATION



See Figure 1


CAUTION
To avoid personal injury, use the Tech 1® scan tool to relieve the gear tension in the hydraulic modulator. This procedure must be performed prior to removal of the brake control and motor assembly.



Click image to see an enlarged view

Fig. Fig. 1: View of the ABS hydraulic modulator/master cylinder assembly-1995 vehicle shown

  1. Disconnect the negative battery cable.
  2.  
  3. Disengage the two solenoid electrical connectors and the fluid level sensor connector.
  4.  
  5. Detach the 6-pin and 3-pin motor pack electrical connectors.
  6.  
  7. Wrap a shop towel around the hydraulic brake lines, then disconnect the four brake lines from the modulator.
  8.  

Cap the disconnected lines to prevent the loss of fluid and the entry of moisture and contaminants.

  1. Unfasten the 2 nuts attaching the ABS hydraulic modulator/master cylinder assembly to the vacuum booster.
  2.  
  3. Remove the ABS hydraulic modulator assembly from the vehicle.
  4.  

To install:
  1. Install the ABS hydraulic modulator assembly to the vehicle. Secure using the two attaching nuts and tighten to 20 ft. lbs. (27 Nm).
  2.  
  3. Uncap and connect the 4 brake pipes to the modulator assembly. Tighten to 13 ft. lbs. (17 Nm).
  4.  
  5. Attach the 6-pin and 3-pin electrical connectors.
  6.  
  7. Engage the fluid level sensor connector and the two solenoid electrical connections.
  8.  
  9. Properly bleed the ABS system, as outlined later in this section.
  10.  
  11. Connect the negative battery cable.
  12.  

 
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