Suzuki Aerio, Verona 2002-06

Hydraulic Control Module

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the negative battery lead.
    WARNING
    The hydraulic unit must not be opened under any circumstances. Reassembling it requires special equipment and facilities.


    NOTE
    The hydraulic unit for ABS has only eight valves while a unit for ABS and STC (stability and traction control) has ten valves. The method for replacing the unit is the same for both types. Check thoroughly when installing the new unit that the unit is the correct type.

  4.  
  5. Secure the brake pedal in the depressed position. Use a pedal jack.
  6.  
  7. Remove the protective cap from the bleed nipple at the left front wheel.
  8.  
  9. Install a plastic hose on the nipple. Open the bleed nipple.
  10.  
  11. Collect the brake fluid in a container.
  12.  
  13. Shut the bleed nipple.
  14.  
  15. Remove the brake pipe between the master cylinder and the ABS hydraulic control module.
  16.  
  17. Disconnect the brake pipes to the wheel brakes from the ABS hydraulic control module.
    NOTE
    Note the position of the pipes in the hydraulic unit.



    Click image to see an enlarged view

    Fig. Disconnecting brake pipes from hydraulic control module

  18.  
  19. Hang the brake pipes on the cross member.
  20.  
  21. Plug the brake pipes and connections for the ABS hydraulic control module and master cylinder.
  22.  
  23. Remove the connector from the control module.
  24.  
  25. Remove the 3 mounting bolts for the bracket by the side member.
  26.  
  27. Raise the ABS hydraulic control module and bracket.
  28.  
  29. Remove or disconnect the following:

    The connector for the pump motor from the control module
     
    The bracket from the ABS hydraulic control module
     
    The control module

    Click image to see an enlarged view

    Fig. Exploded view of hydraulic control module, bracket, and pump

     

  30.  

To install:

  1. Check the control module before installing:

    That none of the pins on the connector are damaged
     
    That there are no contaminants on the mating surfaces between the control module and the ABS hydraulic control module.
     

  2.  
  3. Install or connect the following:
    NOTE
    The ABS hydraulic control module is filled with brake fluid. It is important that the plugs are not removed until the brake pipes are to be connected.


    WARNING
    No ABS, stability and traction control functions are available when there is communication with the Brake Control Module (BCM) because Volvo Diagnostics are activated. The ABS warning lamp flashes for as long as the diagnostics are activated. To cancel the diagnostics before test driving the vehicle, the ignition must be switched off.


    NOTE
    Remember to remove the pedal jack after installing all brake pipes.



    The control module on the ABS hydraulic control module
     
    The bolts. Tighten to 18 inch lbs. (2 Nm)
     



    The new hydraulic unit on the bracket. Tighten the mounting bolts to 71 inch lbs. (8 Nm)
     
    The connector for the pump motor to the control module
     
    The ABS hydraulic control module and bracket
     
    The three bolts. Tighten to 88 inch lbs. (10 Nm)
     
    The brake pipes to the wheel brakes. Tighten to 133 inch lbs. (15 Nm)
     



    The brake pipe between the master cylinder and the ABS hydraulic control module.
     

  4.  


CAUTION
Never disassemble ABS hydraulic unit / control module assembly, loosen blind plug or remove motor. Performing any of these prohibited services will affect original performance of ABS hydraulic unit / control module assembly.


NOTE
Before removal, check hydraulic unit for fluid leakage. If any, repair or replace.

  1. Disconnect negative cable from battery.
  2.  
  3. Disconnect ABS hydraulic unit / control module assembly connector (1) by pull down the lock (2).

    Click image to see an enlarged view

    Fig. Disconnect ABS hydraulic unit/control module assembly connector by pulling down on the lock

  4.  
  5. Using special tool (A) 09950-78220, loosen flare nuts (1) and disconnect brake pipes (2) from ABS hydraulic unit / control module assembly (3).
    NOTE
    Put bleeder plug cap or the like onto pipe to prevent fluid from spilling. Do not allow brake fluid to get on painted surfaces.



    Click image to see an enlarged view

    Fig. Loosen flare nuts and disconnect brake pipes from ABS hydraulic unit/control module assembly

  6.  
  7. Remove three bolts and disconnect take out ABS hydraulic unit / control module assembly (1) from bracket using flat end rod or the like (2).
    CAUTION
    Do not give an impact to hydraulic unit.


    CAUTION
    Use care not to allow dust to enter hydraulic unit.


    CAUTION
    Do not place hydraulic unit on its side or upside down. Handling it in inappropriate way will affect its original performance.



    Click image to see an enlarged view

    Fig. Remove bolts and take out ABS hydraulic unit/control module assembly from bracket

  8.  

To install:

  1. Install hydraulic unit / control module assembly by reversing removal procedure. Tighten the brake pipe flare nut (a) to 11.5 ft. lbs. (16 Nm). Tighten the ABS hydraulic unit/control module assembly bolt to 6.5 ft. lbs. (9 Nm). Tighten ABS hydraulic unit/control module assembly bracket bolt (c) to 16.5 ft. lbs. (23 Nm).

    Click image to see an enlarged view

    Fig. Install the hydraulic unit/control module assembly

  2.  

 
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