GM Lumina/Grand Prix/Cutlass Supreme/Regal 1988-1996

Powermaster III (Hydraulic Unit)

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REMOVAL & INSTALLATION



See Figure 1

Click image to see an enlarged view

Fig. Fig. 1: Powermaster III hydraulic unit

Do not lift or pull the hydraulic unit using the hydraulic unit wiring harness.

  1. Depressurize the Powermaster III completely.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the 30 amp fusible element K from the ABS power center.
  6.  
  7. Unplug the 7-pin vehicle electrical connector from the hydraulic unit harness.
  8.  
  9. Detach the vehicle 10-pin electrical connector from the hydraulic unit harness.
  10.  
  11. Unplug the 2-pin connector from the fluid level sensor.
  12.  
  13. Disconnect the 3 brake pipes from the hydraulic unit. Plug the open lines to prevent fluid loss and contamination.
  14.  
  15. Inside the vehicle, remove the hair pin clip and pushrod from the brake pedal.
  16.  
  17. Remove the 2 attaching nuts from the cowl bracket studs.
  18.  

To avoid damage to the protruding hydraulic unit parts, install unit on J-37116 (or equivalent) holding fixture.

  1. Remove the hydraulic unit.
  2.  

To install:
  1. Lightly lubricate the entire outer surface of the pushrod with silicone grease. Position the hydraulic unit in the vehicle. Guide the pushrod through the grommet.
  2.  
  3. Position the mounting bracket on the cowl bracket studs. Loosely install the attaching nuts.
  4.  
  5. Install the pushrod on the brake pedal mounting pin and install the hair pin clip.
  6.  
  7. Install the 2 attaching nuts. Tighten the nuts to 20 ft. lbs. (27 Nm).
  8.  
  9. Install the 3 brake pipes to the hydraulic unit and tighten to 15 ft. lbs. (17 Nm).
  10.  
  11. Attach the 3 electrical connectors to the hydraulic unit or its harness. Make sure all CPA locking pins are installed.
  12.  
  13. Install the 30 amp fusible element.
  14.  
  15. Adjust the brakelight switch.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Properly bleed the ABS brakes, as outlined in this section.
  20.  

 
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