Repair Procedure
Service Advisor
1. Look for a completion label for this recall on the driver's doorjamb.
^ If you find either label, this vehicle has already been inspected. Return the vehicle to the customer.
^ If you do not find either label, continue to step 2.
2. Enter the VIN into the Dealer Communication System (DCS).
^ If the recall does not apply to this vehicle's VIN, place a "NOT AFFECTED" label on the driver's doorjamb and return the vehicle to the customer.
^ If the recall does apply to this vehicle's VIN, continue to "Technician."
Technician
1. Using the special tool, measure the clearance between the brake line and the left front upper control arm. To get the proper measurement, the vehicle must be sitting on the ground at the proper ride height.
^ If there is a minimum of 10 mm clearance (the middle part of the special tool passes between the brake line and the control arm), no repair is needed. Go to step 36 to complete the campaign.
^ If there is not a minimum of 10 mm clearance (the middle part of the special tool will not pass between the brake line and the control arm), continue to step 2 to replace the brake line.
2. Raise the vehicle. Remove the left front wheel.
3. Remove the inner mud flap.
4. Remove the battery hold-down bracket.
5. Disconnect the window washer tube from the hood.
6. Remove the anti-theft horn bracket and A/T vent tube.
7. Remove the cruise control actuator cable clamp bolt.
8. Remove the A/C suction line clamp bolt.
9. Unclamp the A/C high pressure line from the bulkhead.
10. Disconnect the vapor hose from the charcoal canister (see Engine Driveability and Emissions manual).
11. Disconnect the air cleaner cover from the housing. Remove the cover, mass air flow sensor, and intake duct.
12. Remove the charcoal canister and bracket.
13. Disconnect the vacuum hose from the power brake booster.
14. Disconnect the electrical connector from the brake master cylinder.
15. Remove the master cylinder from the power brake booster. Do not disconnect any of the brake lines from the master cylinder.
16. Disconnect the brake line from the flexible hose at the left front caliper.
17. Disconnect the other end of this same brake line from the ABS unit.
18. Remove the brake line from the vehicle.
NOTICE
Brake fluid will damage the paint. Immediately clean any spilled brake fluid off the painted surfaces with water.
19. Select the new long brake line. Blow clean, dry compressed air through the line to remove any contaminants.
20. Route the new brake line along the right front fender and along the rear bulkhead. Clamp it in place with the original clamps.
21. Connect the brake line to the ABS unit. Tighten the fitting to 16 N.m (12 lb-ft).
22. Loosely install the union on the end of the brake line.
23. Blow clean, dry compressed air through the new short brake line to remove any contaminants.
24. Place the brake line in position. Loosely connect it to the union and the flexible brake hose.
25. Torque the fitting at the flexible brake hose to 16 N.m (12 lb-ft). Hold the brake line as you tighten the fitting to maintain proper clearance to the control arm.
26. Torque the brake line fitting at the union to 16 N.m (12 lb-ft).
27. Reinstall all removed parts in the engine compartment. Install the master cylinder with new gaskets on both sides of the spacer. Torque the master cylinder mounting nuts to 13 N.m (113 lb-in).
28. Remove the 40A ABS fuse (FL6) from the under-hood fuse/relay box.
29. Start the engine.
30. Bleed the right front brake caliper.
31. Bleed the left front brake caliper.
32. Turn off the engine. Reinstall the 40A ABS fuse.
33. Reinstall the inner mud flap.
34. Reinstall the left front wheel. Torque the wheel nuts to 118 Nm (87 lb-ft).
35. Lower the vehicle, and clean up any spilled brake fluid.
36. Install the Recall Campaign Completion label on the driver's doorjamb below the Manufacturer's Identification label.