B. - Repair Procedure

B. REPAIR PROCEDURE





PARTS INCLUDED WITH DSC CONTROL MODULE (CM)

1. Connect the M-MDS to the DLC-2 (A).





2. After the vehicle is identified, select the following items from the M-MDS screen menu in this order:

^ Select "Toolbox icon."

^ Select "Module Programming."

^ Select "Programmable Module Installation."

^ Select "ABS."

3. When the screen of the M-MDS displays "Install a new module in vehicle," go to next step.

4. Write down the customer's radio station presets (if applicable).





5. Remove the battery cover (A).

6. Disconnect the positive and negative battery cables (B and C).

7. Remove the battery duct (D).

8. Remove the battery box (E).

9. Remove the battery clamp (F).

10. Remove the battery (G).

11. Remove the PCM cover (H).

12. Disconnect the PCM connectors (I).

13. Remove the battery tray and PCM components (J).





14. Disconnect the reserve hose from the master cylinder reserve tank by pressing the point indicated by the arrow (vehicles with M/T).

15. Disconnect the DSC connector by doing the following:

^ Press the tabs on the connector cover.

^ Pull the connector cover up.

^ Pull the connector toward the front of the vehicle.





16. Apply protective tape over the wiring harness connector to prevent brake fluid from entering.

17. Place a rag under the DSC unit to catch any brake fluid that might leak.





18. Place a matching mark (A) on each brake line and the DSC unit so that the brake lines go back in the same place, then remove the brake lines from the DSC HU/CM unit.

CAUTION:
Brake fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. If it is spilled, wipe it off immediately.

19. Insert the plastic caps into the brake line holes of the DSC unit to prevent foreign material from entering.

20. Remove the DSC bracket bolt.





21. Move the bracket in the direction of the arrow and remove the DSC HU/CM and bracket from the body.

22. Remove the DSC control module (CM) (A) from DSC HU/CM unit by doing the following:





^ Assemble the fixing adaptor (B) for the pump motor (C) with the supplied (yellow) plastic screws as shown before disassembling. This will keep the pump motor in place during the disassembly / assembly of the unit.

^ Remove both Torx head screws (D) from the pump motor and discard - they are not needed anymore.

WARNING:
The pump motor must NOT be removed from the DSC hydraulic unit (HU) (E).





23. Insert the new pump motor adaptor (F) into the new DSC CM as shown, then firmly press it up to the limit stop and the locks snap.

NOTE:
The assembly force to fit the pump motor adaptor into the DSC CM is maximum 130 N.

24. Install the new DSC CM to the DSC HU.

25. Install the new Torx head screws for the pump motor.

Tightening torque: 5.5 +/- 0.5 Nm (4.6 +/- 0.37 ftlb)

26. Remove the fixing adaptor and plastic caps from the pump motor.

27. Install the DSC CM/HU and bracket to the body.

NOTE:
To make it easier to start the brake lines in the DSC unit, do not install the bolt for the DSC bracket until the brake lines are connected.





28. Install the brake lines to the DSC unit.

29. Install the bolt for the DSC unit bracket.

Tightening torque: 7.8 - 10.8 Nm (5.75 - 8 ftlb)

30. Connect the DSC connector.

31. Install the reserve hose to the master cylinder (vehicles with M/T).

32. Bleed the brakes and check for leaks at the DSC unit.

33. Install the battery tray and PCM components.

34. Connect the PCM connectors.

35. Install the PCM cover.

36. Install the battery.

37. Install the battery clamp.

38. Install the battery box.

39. Install the battery duct.

40. Connect the positive and negative battery cables.

41. Install the battery cover.

42. Configure the DSC unit according to the instructions on the M-MDS,resuming from where it displayed "Install a new module in the vehicle."

43. Perform the initialization procedures for the lateral acceleration sensor and brake fluid pressure sensor by selecting the following items from the M-MDS screen menu in this order:

^ Select "Toolbox icon."

^ Select "Chassis."

^ Select "ABS/DSC."

^ Select "Sensor Initialization."

NOTE:
Perform both sensor initialization before test driving the vehicle for 5 minutes.

44. Check and clear any DTCs.

45. Enter the customer's radio station presets (if applicable).