Solstice 2006-2008, Sky 2007-2008

Control Valve

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Removal & Installation



With Active Brake Control System (Jl4)
  1. Before servicing the vehicle, refer to the Precautions Section.
    WARNING
    Always connect or disconnect the wiring harness connector from the Electronic Brake Control Module (EBCM) with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM.

  2.  
  3. Turn the ignition switch to the OFF position.
  4.  
  5. Thoroughly clean the EBCM to Brake Pressure Modulator Valve (BPMV) area of any accumulated dirt and foreign material.
  6.  
  7. Disconnect the brake fluid level indicator switch electrical connector.
  8.  
  9. Disconnect the vacuum brake booster vacuum sensor electrical connector.
  10.  
  11. Release the wiring harness retainer from the master cylinder mounting stud and position the wiring harness downward.
  12.  
  13. Remove and discard the 2 master cylinder nuts.
  14.  
  15. If equipped, disconnect the clutch master cylinder hose from the brake master cylinder reservoir.
  16.  
  17. Cap the brake fluid reservoir outlet and plug the clutch master cylinder hose inlet to prevent brake fluid loss and contamination.
  18.  
  19. Remove the 2 master cylinder brake pipe fittings from the BPMV
  20.  
  21. Cap the brake pipe fittings and plug the BPMV inlet ports to prevent brake fluid loss and contamination.
  22.  
  23. Remove the brake master cylinder and master cylinder brake pipes as an assembly.
  24.  
  25. Remove the 2 rear brake pipe fittings from the BPMV.
  26.  
  27. Cap the brake pipe fittings to prevent brake fluid loss and contamination.
  28.  
  29. Remove the 2 front brake pipe fittings from the BPMV.
  30.  
  31. Cap the brake pipe fittings to prevent brake fluid loss and contamination.
  32.  
  33. Lift the locking tabs on the lower edge of the EBCM electrical connector and disconnect the electrical connector.
  34.  
  35. Position the EBCM electrical connector and the wiring harness toward the front of the vehicle.
  36.  
  37. Remove the 2 upper BPMV bracket bolts.
  38.  
  39. Loosen, but do not remove the lower BPMV bracket bolt.
  40.  
  41. Remove the brake modulator and bracket assembly.
  42.  
  43. Remove the BPMV bolt.
  44.  
  45. Carefully separate the BPMV from the bracket. Do not pry against the accumulator covers on the underside of the BPMV.

    Click image to see an enlarged view

    Fig. BPMV, bracket and bolt

  46.  
  47. Remove the EBCM bolts.
  48.  
  49. Carefully pull the EBCM from the BPMV.
    WARNING
    Do not pry the components apart.

  50.  

To install:

  1. If installing a new BPMV, remove and discard the EBCM O-ring seals.
  2.  
  3. If reinstalling the BPMV, clean the sealing surface of the BPMV with denatured alcohol and allow to dry.
    WARNING
    Ensure the brake pressure switch is properly aligned to the BPMV when installing the EBCM. Do not force the components together.

  4.  
  5. Carefully install the EBCM to the BPMV.
  6.  
  7. Install the EBCM bolts and tighten to 20 inch. lbs. (2.3 Nm).
  8.  
  9. Inspect the BPMV bracket insulators for damage and replace if necessary.
  10.  
  11. Install the BPMV to the bracket.
  12.  
  13. Install the BPMV bolt and tighten to 97 inch. lbs. (11 Nm).
  14.  
  15. Install the brake modulator and bracket assembly. Align the BPMV bracket to the lower bracket bolt.
  16.  
  17. Install the 2 upper brake modulator bracket bolts and tighten to 89 inch. lbs. (10 Nm).
  18.  
  19. Install the lower brake modulator bracket bolt and tighten to 89 inch. lbs. (10 Nm).
  20.  
  21. Install the 2 rear brake pipe fittings to the BPMV and tighten to 15 ft. lbs. (20 Nm).
  22.  
  23. Install the 2 front brake pipe fittings to the BPMV and tighten to 15 ft. lbs. (20 Nm).
  24.  
  25. Connect the EBCM electrical connector. Ensure the tabs on the cam lever are securely locked in place.
  26.  
  27. Install the brake master cylinder and brake pipes assembly to the vacuum brake booster.
  28.  
  29. Install the 2 master cylinder brake pipe fittings to the BPMV and tighten to 15 ft. lbs. (20 Nm).
  30.  
  31. If equipped, connect the clutch master cylinder hose to the brake master cylinder reservoir.
  32.  
  33. Install 2 new brake master cylinder nuts and tighten to 15 ft. lbs. (20 Nm).
  34.  
  35. Position the wiring harness upward and install the wiring harness retainer to the master cylinder mounting stud on the vacuum brake booster.
  36.  
  37. Connect the brake booster vacuum sensor electrical connector.
  38.  
  39. Connect the brake fluid level indicator switch electrical connector.
  40.  
  41. If a new EBCM was installed, program the EBCM.
    NOTE
    A new BPMV comes with both the primary and secondary circuits pre-filled with brake fluid. If the ignition key has not been cycled after installation, only a base brake bleed is necessary.

  42.  
  43. Bleed the hydraulic brake system.
  44.  
  45. Observe the brake pedal feel after performing the diagnostic system check. If the pedal now feels spongy, air may have been introduced into the secondary hydraulic circuit of the brake modulator which then may have been introduced into the primary circuit. If the pedal feels spongy, perform the antilock brake system automated bleed procedure.
  46.  

Without Active Brake Control System (Jl4)
  1. Before servicing the vehicle, refer to the Precautions Section.
    WARNING
    Always connect or disconnect the wiring harness connector from the Electronic Brake Control Module (EBCM) with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM.

  2.  
  3. Turn the ignition switch to the OFF position.
  4.  
  5. Thoroughly clean the EBCM to Brake Pressure Modulator Valve (BPMV) area of any accumulated dirt and foreign material.
  6.  
  7. Remove the EBCM electrical connector, lift the connector locking lever upward.
    NOTE
    Note the location of the brake pipe fittings for installation.

  8.  
  9. Remove brake pipe fittings and cap the fittings to prevent brake fluid loss and contamination.
  10.  
  11. Plug the BPMV inlet and outlet ports to prevent brake fluid loss and contamination.
  12.  
  13. Carefully position the brake pipes aside to provide access to remove the BPMV assembly.
  14.  
  15. Remove the BPMV assembly bracket mounting bolts.
  16.  
  17. Remove the BPMV to bracket mounting bolt.
    WARNING
    Do not pry against the accumulator covers on the underside of the brake pressure modulator assembly to release the mounting pins from the bracket insulators.


    WARNING
    Do not remove the mounting pins unless it is necessary to aid in releasing the modulator assembly from the bracket.



    Click image to see an enlarged view

    Fig. BPMV and related parts

  18.  

To install:

  1. If installing a new BPMV, remove the EBCM. Refer to electronic brake control module replacement.
  2.  
  3. If installing a new BPMV, remove and discard the EBCM O-ring seals.
  4.  
  5. If reinstalling the BPMV, clean the sealing surface of the BPMV with denatured alcohol and allow to dry.
  6.  
  7. Install the BPMV to the bracket.
  8.  
  9. Install the BPMV bolt and tighten to 97 inch. lbs. (11 Nm).
  10.  
  11. Install the brake modulator and bracket assembly.
  12.  
  13. Install the modulator bracket bolts and tighten to 89 inch. lbs. (10 Nm).
  14.  
  15. Install the 6 brake pipe fittings to the BPMV and tighten to 15 ft. lbs. (20 Nm).
  16.  
  17. Connect the EBCM electrical connector. Ensure the tabs on the cam lever are securely locked in place.
  18.  
  19. If a new EBCM was installed, program the EBCM.
    NOTE
    A new BPMV comes with both the primary and secondary circuits pre-filled with brake fluid. If the ignition key has not been cycled after installation, only a base brake bleed is necessary.

  20.  
  21. Bleed the hydraulic brake system.
  22.  
  23. Observe the brake pedal feel after performing the diagnostic system check. If the pedal now feels spongy, air may have been introduced into the secondary hydraulic circuit of the brake modulator which then may have been introduced into the primary circuit. If the pedal feels spongy, perform the antilock brake system automated bleed procedure.
  24.  

 
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