GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2008 🢒 Astra 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Brake Pressure Modulator Valve Replacement

Removal Procedure

    Important: It is essential to comply with the instructions for the hydraulic modulator and the ABS control unit. Refer to ABS Control Unit General Repair Specification.

  1. Remove the cover of the brake fluid reservoir.
  2. Siphon out as much brake fluid as possible with a siphon bottle.
  3. Remove the battery.
    4. 3.1. Remove the ground connection nut and remove the terminal from the battery.
    3.2. Remove the positive connection nut and remove the positive terminal from the battery.
    3.3. If present, remove the thermal protection (battery jacket).
    3.4. Remove the bracket that holds the battery.

    Remove the bolt. Use a magnetic nut to prevent the bolt from falling into the engine compartment.

    3.5. Remove the battery.

    Object Number: 1936696 Size: SH
  4. Remove the battery support.

    5. Remove the 3 bolts (2).

    Important: Cooling system remains sealed.

  5. Remove the coolant surge tank.
    6. 5.1. Remove the securing clip of the surge tank. Use a hook and pull the clip to the front of the vehicle.
    5.2. Disconnect the wiring harness plug, below the surge tank, from the coolant level sensor.
    5.3. Pull the coolant surge tank to the front of the vehicle and set the coolant surge tank aside.

    Object Number: 1937847 Size: SH
  6. Remove the hydraulic modulator.
    7. 6.1. Disconnect the hydraulic modulator wiring harness plug.
    6.2. Remove the 6 hydraulic lines (2).
    6.3. Install the 6 sealing plugs on the hydraulic modulator.
    6.4. Remove the 3 bolts (1).

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.

  1. Install the hydraulic modulator.

    2. Tighten
    Tighten the 3 hydraulic modulator bolts to 8 N·m (71 lb in).

    1.1. Remove the 6 sealing plugs from the hydraulic modulator.
    1.2. Install the 6 hydraulic lines.

    Tighten
    Tighten the 6 hydraulic lines retaining bolts to 14 N·m (124 lb in).

    1.3. Connect the hydraulic modulator wiring harness plug.
  2. Install the coolant surge tank to the mounting.

    3. Connect the wiring harness plug for the coolant level sensor.

  3. Install the battery support.

    4. Tighten
    Tighten the 3 battery support bolts to 10 N·m (89 lb in).

    3.1. Install the wiring harness plug.
    3.2. Install the coolant hose at the battery tray.
    3.3. Install the wiring harness.

    Install the 2 cable ties.

  4. Install the battery.
    5. 4.1. Install the battery bracket.

    Tighten
    Tighten the battery bracket bolt to 15 N·m (11 lb ft).

    4.2. If present, install the thermal protection.
    4.3. Install the battery positive connection to the positive terminal.

    Tighten
    Tighten the battery positive connection nut to 5 N·m (44 lb in).

    4.4. Install the battery ground connection to the ground terminal.

    Tighten
    Tighten the battery ground connection nut to 5 N·m (44 lb in).

  5. Bleed the brake system. Refer to Hydraulic Brake System Bleeding.
  6. Top up the brake fluid reservoir to the MAX marking.
  7. Install the cover onto the brake fluid reservoir.
  8. For programming procedures, refer to Control Module References.