Skylark L4-138 2.3L SOHC VIN 3 MFI QUAD 4 (1992)
IMPORTANT
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If ABS hydraulic modulator is to be replaced, install three gears in same location on replacement hydraulic modulator. Refer to gear
replacement in this section.
IMPORTANT
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No repair of the motor pack assembly or ABS hydraulic modulator assembly is authorized. Replace as assemblies.
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Refer to Brakes and Traction Control / Brakes / Antilock Brake System / Master Cylinder, ABS / Service and Repair for repair of master
cylinder.See: Brake Master Cylinder/Service and Repair
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Use new transfer tube assemblies when assembling the ABS hydraulic modulator and master cylinder assembly.
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Make sure two 0-rings are properly installed on each transfer tube assembly.
ASSEMBLE
1. Two transfer tube assemblies.
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Lubricate transfer assembly 0-rings with clean brake fluid.
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Install transfer tube assemblies in ports in ABS hydraulic modulator and push in by hand to bottom.
2. Lubricate new thru-bolt 0-rings with clean brake fluid and install into the master cylinder and modulator.
3. ABS hydraulic modulator to master cylinder.
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Clamp mounting flange of master cylinder in vise.
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Hold ABS hydraulic modulator and rock into position on master cylinder, inserting transfer tube assemblies into master cylinder ports.
4. Two modulator to master cylinder thru-bolts.
TIGHTEN
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Bolts to 16 Nm (12 lb. ft.).
NOTICE: With the modulator upside down and the gears facing you, rotate each gear on the ABS hydraulic modulator counterclockwise until
movement stops. This will position the pistons very close to the top of their travel, simplifying bleeding procedures.
5. Motor pack assembly to ABS hydraulic modulator and master cylinder assembly.
IMPORTANT
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Take care in handling the motor pack assembly. If dropped or damaged during handling, the motor pack assembly must be replaced.
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Align each of three motor pack pinions with ABS hydraulic modulator gears.
6. Four Torx head screws.
TIGHTEN
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Torx head screws to 5 Nm (40 lb. in.).
7. Gear cover to ABS hydraulic modulator and master cylinder assembly.
8. Six Torx head screws.
TIGHTEN
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Torx bolts to 3 Nm (27 lb. in.).
Gear Replacement
CAUTION: To help avoid personal injury, due to a retained load on the ABS hydraulic modulator, the gear tension relief function of the Tech
1 must be performed prior to removal of the ABS hydraulic modulator/master cylinder assembly. Refer to "Gear Tension Relief Sequence".
NOTICE: The following service procedures shall be performed only after the hydraulic modulator/master cylinder assembly has been removed from the
vehicle. Do not perform these procedures with the unit installed on the vehicle. Complete overhaul of the hydraulic modulator/master cylinder assembly
is not authorized only the following steps. These steps will break the unit down into major components for replacement purposes.
GEAR REPLACEMENT
IMPORTANT: Do not attempt to repair damaged motor packs or hydraulic modulators. Other than modulator drive gear replacement, repair of these
assemblies is not authorized. Do not lubricate or oil gears or motor pack.
CAUTION: The modulator drive gears are under spring load and will turn during disassembly. After removing hydraulic modulator drive gear
cover, exercise extreme care not to place fingers into the gear set, since fingers can be pinched by rotating gears.
DISASSEMBLE
1. Hydraulic modulator/master cylinder assembly.