TC/ABS Hydraulic Brake Unit
TC/ABS Hydraulic Brake Unit
Object code: 52150
To remove
1 Remove the lower dash panel from above the pedal assembly.
2 Remove the pin retaining clip and withdraw the pin from the hydraulic brake unit pushrod.
3 Disconnect the battery cables and remove the battery.
4 To gain access to the hydraulic brake unit, remove the following:
^ clips securing the positive battery cable to the battery tray.
^ terminal block (with positive battery cable) from the front of the battery tray
^ connector from the rear of the battery tray (cars with DI:three connectors)
^ two nuts for the steady bar
^ TC/ABS control unit (move to one side)
5 Remove the battery tray.
6 Undo the ABS electrical distribution box and move it to one side.
7 Siphon off the brake fluid from the reservoir.
8 Remove the left-hand front wheel and both wing liners.
9 Remove the steady bar between the wheel housing and engine subframe.
10 Cut the cable tie and disconnect all electrical leads from the hydraulic brake unit:
^ high-pressure pump motor (1)
^ fluid-level switch on reservoir (2)
^ main valve (3)
^ pressure switch (4)
^ ABS valve block (5)
^ TC valve block (6)
11 Remove the battery tray bracket from the hydraulic brake unit.
12 Disconnect the clutch cylinder hose (cars with manual gearbox) and plug the end of the hose.
Avoid letting any brake fluid run out of the hose, as this could allow air to get into the clutch system.
13 Disconnect the brake pipes from the valve block and plug the pipe ends.
14 Remove the accumulator, using an 8mm Allen key.
15 Remove the four retaining nuts for the hydraulic brake unit, located on the bulkhead partition at the pedal assembly.
16 Lift Out the hydraulic brake unit.
To fit
1 Lift the hydraulic brake unit into place, simultaneously guiding the pushrod into position at the pedal assembly.
2 Reconnect the pushrod linkage, fitting the pin and pin retaining clip.
3 Tighten the four hydraulic brake unit retaining nuts located on the bulkhead partition at the pedal assembly.
Tightening torque:26 ± 4 Nm (19 ± 3 lbf ft)
4 Fit the accumulator back in place.
Tightening torque: 37 ± 3 Nm (28 ± 3 lbf ft)
5 Remove the plugs and reconnect the brake pipes to the valve block.
6 Reconnect the hose to the clutch cylinder.Check that the hose still contains brake fluid.
7 Secure the battery tray bracket to the hydraulic brake unit
8 Reconnect all electrical leads to the hydraulic brake unit:
^ high-pressure pump motor (1)
^ fluid-level switch on reservoir (2)
^ main valve (3)
^ pressure switch (4)
^ ABS valve block(5)
^ TC valve block (6)
9 Fit the steady bar between the wheel housing and engine subframe.
10 Refit the battery tray and the TC/ABS control unit. Tighten the steady bar retaining nuts.
11 Refit the following:
^ two cable clips for the positive cable on the battery tray
^ terminal block (with positive cables) on the front of the battery tray
^ connector (or connectors) at the rear of the battery tray
^ ABS electrical distribution box
12 Fit the battery and connect the cables.
13 Top up the system with brake fluid to DOT 4 specification
14 Reconnect the pushrod linkage, fitting the pin and pin securing clip.
15 Switch on the ignition and check that the high-pressure pump is working.
16 Bleed the brake system.
17 Check for leaks in the brake system and verify that the brake and ABS warning lamps go out as they should.
18 Refit the wing liners and front wheel.
19 Refit the lower dash panel at the pedal assembly.