Cavalier L4-2.2L VIN 4 (1998)
No repair of the ABS brake modulator is authorized. Replace the ABS brake modulator as an assembly.
IMPORTANT: Use new transfer tube assemblies when assembling the ABS brake modulator/master cylinder assembly. Be sure to properly install
two O-rings on each transfer tube.
1. Use the following procedure in order to install the two transfer assemblies:
1.1. Lubricate the transfer tube assembly O-rings with clean brake fluid.
1.2. Install the transfer tube assemblies into ports of the ABS brake modulator.
Push the tube assemblies in by hand to the bottom of the ports.
2. Lubricate the new banjo bolt 0-ring with clean brake fluid.
3. Install the banjo bolt 0-ring into the master cylinder and the ABS brake modulator.
4. Use the following procedure in order to install the ABS brake modulator onto the master cylinder:
4.1. Clamp the mounting flange of the master cylinder in a vise.
4.2. Hold the ABS brake modulator and rock the modulator into position on the master cylinder.
4.3. Insert the transfer tube assemblies into the master cylinder ports.
5. Install two ABS brake modulator to master cylinder banjo bolts.
Tighten
Tighten the banjo bolts to 24 Nm (18 ft. lbs.).
6. With the ABS brake modulator positioned upside down, and the gears facing you, rotate each ABS brake modulator gear counterclockwise until
movement stops.
The procedure causes the following conditions:
^
The pistons are positioned very close to the top of the modulator bore.
^
The brake bleeding procedure is simplified.
7. Install the ABS brake motor pack (1) onto the brake modulator/master cylinder assembly (2).
8. Install the four Torx head screws (6) that retain the motor pack (1) to the brake modulator (2).
Tighten
Tighten the four Torx head screws to 5 Nm (44 inch lbs.).
9. Install the gear cover (4) to the brake modulator/master cylinder assembly (2).
10. Install the Torx head screws (5) that retain the gear cover (4).
Tighten
Tighten the Torx head screws to 4 Nm (36 inch lbs.).
11. Install the brake modulator/master cylinder assembly. Refer to Brake Modulator/Master Cylinder Asm Replacement
12. Perform the Diagnostic System Check
