Aveo, G3 and Wave Brake Pressure Modulator Replacement
Chevrolet Aveo, Pontiac G3 and Pontiac Wave Brake Pressure Modulator ReplacementWarning
Brake fluid may irritate eyes and skin. In case of contact, take the following actions:
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Eye contact-rinse thoroughly with water.
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Skin contact-wash with soap and water.
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If ingested-consult a physician immediately.
1. Drain the brake fluid from the brake system.
Warning
Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. For Vehicles equipped with OnStar(R) (UE1) with Back Up Battery: The Back Up Battery is a redundant power supply to allow limited OnStar(R) functionality in the event of a main vehicle battery power disruption to the VCIM (OnStar(R) module). Do not disconnect the main vehicle battery or remove the OnStar(R) fuse with the ignition key in any position other than OFF. Retained accessory power (RAP) should be allowed to time out or be disabled (simply opening the driver door should disable RAP) before disconnecting power. Disconnecting power to the OnStar(R) module in any way while the ignition is On or with RAP activated may cause activation of the OnStar(R) Back-Up Battery (BUB) system and will discharge and permanently damage the back-up battery. Once the Back-Up Battery is activated it will stay on until it has completely discharged. The BUB is not rechargeable and once activated the BUB must be replaced.
2. Disconnect the negative battery cable and then disconnect the positive battery cable.
3. Remove the nuts from the battery rods that fasten the battery hold-down bar clamp.
4. Remove the battery from the vehicle.
5. Unlock the retaining tabs on the fuse block and remove the cover.
Note
Do not separate the fuse block from the housing. Do not remove the wiring harness from the fuse block.
6. Remove the fuse block positive battery cable nut (1) and the positive battery cable (2).
Note
Illustration shows fuse block out of housing for illustration purposes only. Remove the fuse block and housing as one assembly.
7. Remove fuse block housing bolt (1) and fuse block housing (2) from current location with fuse block and housing as one assembly.
Caution
The fuse block wiring harness will limit where you can place the fuse block. Do not attempt to move the fuse block further than what the wiring harness will permit.
8. Move fuse block and fuse block housing away from work area in the engine compartment.
9. Disconnect the electrical connector from the master cylinder reservoir.
Note
Do not remove the radiator surge tank coolant feed hose. Plug surge tank overflow outlet on the tank, if required.
10. Disconnect the radiator surge tank overflow hose located next to the radiator surge tank attachment fasteners.
11. Remove radiator surge tank attachment nuts.
Caution
The radiator surge tank coolant feed hose will limit where you place the radiator surge tank. Do not attempt to move the radiator surge tank further than the coolant feed hose will permit.
12. Move radiator surge tank away from work area in the engine compartment.
13. Disconnect the electronic brake control module (EBCM) wiring harness connector.
14. Cover the connector and the socket with shop cloths to protect them from brake fluid.
Note
Take care not to allow air into the hydraulic unit or into the brake pipes from the master cylinder. If air gets into the hydraulic unit, it will require a bleeding procedure using a scan tool programmed for the ABS 5.3 system. As long as no air enters the hydraulic unit, a simple bleeding procedure is all the system will require.
15. Remove the brake pipes from the brake pressure modulator valve (BMPV) assembly.
16. Plug the brake pipes.
17. Remove the mounting bracket bolts on the BMPV assembly.
18. Remove the ABS module bracket assembly from vehicle.
19. Remove the ABS module from bracket.
20. Remove the mounting pins (1) from ABS module.
21. Remove the fastners (2) seuring the HCU to the EBCM.
22. Install new HCU on the EBCM. Tighten mounting bolts to 1.8 Nm (16 lb-ft).
23. Install ABS module mounting pins. Tighten mounting pins: 8 Nm (6 lb-ft).
24. Install the brake modulator assembly to the modulator bracket.Tighten mounting bolts: 8 Nm (6 lb-ft).
25. Install the BPMV assembly into the mounting bracket. Secure with two nuts and tighten to 16 Nm (12 lb-ft).
26. Remove the plugs from the brake pipes and connect the brake pipes to the BPMV assembly and tighten to 22 Nm (16 lb-ft).
27. Connect the wiring harness EBCM connector.
28. Place fuse block assembly back into its original location.
Note
Illustration shows fuse block out of housing for illustration purposes only. Install the fuse block and housing as one assembly.
29. Install the fuse block housing bolts (1) and tighten to 7 Nm (62 lb in).
30. Install the fuse block positive battery cable nut (1) and the positive battery cable (2) and tighten to 10 Nm (89 lb in).
31. Install fuse block cover.
32. Connect the master cylinder electrical connector.
33. Place the radiator surge tank into its original location.
34. Install the radiator surge tanks attachment nuts.
35. Connect the radiator surge tank overflow hose.
36. Install the battery into the tray.
37. Fasten the bar clamp to the battery by loosely attaching the battery rods from the battery tray cutouts through the bar clamp holes, and loosely tightening the nuts.
38. Tighten the battery retainer clamp-to-battery rod nuts to 4 Nm (35 lb in).
39. Connect the negative and positive battery cables.
40. Tighten the battery cable nuts to 4.5 Nm (40 lb in).
Note
Fill the master cylinder reservoir with brake fluid. Ensure the master cylinder is at least 1/2 full of fluid during the brake bleeding operation. Fill brake system with Delco Supreme 11 Brake Fluid (P/N 19299818 USA, P/N 19299819 Canada).
41. Bleed the brake system. Refer to Hydraulic Brake System Bleeding in SI.
42. Place a copy of the Owner Manual Supplement (found on the next page) in the customer's owner manual.