Skylark L4-144 2.4L DOHC VIN T SFI (1997)
Hydraulic Assembly: Service and Repair
Hydraulic Modulator
DISASSEMBLE
1. Hydraulic modulator/master cylinder assembly.
2. Torx head screws attaching gear cover.
3. Remove gear cover.
4. Four Torx head screws attaching motor pack to hydraulic modulator.
5. Remove motor pack:
6. Two hydraulic modulator to master cylinder banjo bolts, separate modulator from master cylinder.
7. Two transfer tubes with 0-rings from master
8. cylinder or hydraulic modulator. Banjo bolt. 0-rings from master cylinder and hydraulic modulator. If hydraulic modulator is to be replaced, install
the three gears in the same location on replacement hydraulic modulator. No repair of the hydraulic modulator is authorized. Replace as an
assembly. Use new transfer tube assemblies when assembling the hydraulic modulator/master cylinder assembly. Make sure two 0-rings are
properly installed on each transfer tube.
ASSEMBLE
1. Two transfer assemblies. Lubricate transfer tube assembly 0-rings with clean brake fluid. Install transfer tube assemblies in ports in hydraulic
modulator and push in by hand to bottom.
2. Lubricate new banjo bolt 0-ring with clean brake fluid and install into the master cylinder and hydraulic modulator.
3. Hydraulic modulator to master cylinder. Clamp mounting flange of master cylinder in a vise. Hold hydraulic modulator and rock into position On
master cylinder, inserting transfer tube assemblies into master cylinder ports.
4. Two modulator to master cylinder banjo bolts. Tighten Banjo bolts to 24 Nm (18 ft. lbs.).
5. With the hydraulic. modulator upside down, and the gears facing you, rotate each hydraulic modulator gear counterclockwise until movement
stops. This procedure will position the pistons very close to the top of the hydraulic modulator bore.
6. Motor pack to hydraulic modulator/master cylinder assembly.
7. Four Torx head screws. Tighten Torx head screws to 5 Nm (44 inch lbs.).
8. Gear cover to hydraulic modulator/master cylinder assembly. Tighten Torx screws to 4 Nm (36 inch lbs.).
