C. Replace Pump/Motor Assembly

1. With the ignition key in the OFF position, open the test fixture valve and then pump the brake pedal a minimum of 40 times. A noticeable change in the pedal feel will occur when the accumulators are discharged.

WARNING:
Brake system is under extreme pressure. The hydraulic control unit (HCU) may be charged with hydraulic pressure up to 2200 psi. Failure to de-pressurize the accumulators could result in personal injury and/or damage to painted surfaces. Wear safety goggles when disconnecting system fluid lines.

2. When a definite increase in pedal pressure is felt, pump the pedal a few additional times to ensure removal of all hydraulic pressure from the brake system.

3. Disconnect any routing clips which attach the high and/or low pressure fluid lines to the body or vehicle components.





4. Disconnect the low pressure hose (Figure 11) at the HCU.

5. Disconnect the high pressure hose assembly from the test fixture.

6. Disconnect the 10-way wiring connector from the test fixture and reconnect it to the HCU.

7. Remove the test fixture (Special Tool # 6997).

8. Cap all openings on the reservoir and HCU to prevent brake fluid from leaking.

9. Disconnect all electrical connectors (including pump/motor) that run across the engine compartment in the area around the pump/motor assembly high and low pressure hoses.





10. Remove the pump/motor assembly front heat shield to mounting bracket bolt. Remove the heat shield from the pump/motor assembly (Figure 12).

11. Lift pump/motor assembly from mounting bracket and remove from vehicle.

12. Remove high and low pressure hoses from pump/motor assembly.

13. Lubricate the high and low pressure hose 0-rings with clean brake fluid and position on new pump/motor assembly. Tighten banjo bolt to 124 in-lbs (14 N.m).

14. Position new pump/motor assembly in mounting bracket.

15. Position heat shield over pump/motor on mounting bracket and install attaching bolt.

16. Remove caps from reservoir and HCU openings.

17. Attach high pressure hose to HCU and tighten fitting to 145 in-lbs (16 N.m).

18. Connect low pressure hose to HCU and tighten clamp to 10 in-lbs (1 N.m).

19. Connect pump/motor assembly wiring harness to underhood wiring harness.

20. Reconnect all underhood wiring connectors.

21. Reconnect all routing clips that secure the high and/or low pressure hoses to the body or other components.

22. Proceed to Section D.