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Home >> Saturn >> 2003 >> Ion 1 Automatic >> Repair and Diagnosis >> Brakes >> Traction Control >> Antilock Brake System >> Repair Instructions >> Brake Modulator Assembly Replacement >> Installation Procedure

Installation Procedure

IMPORTANT: When installing a new brake modulator assembly, do NOT remove the shipping plugs from the pipe ports until after installation into the vehicle.
  1. Install the brake modulator assembly to the modulator bracket.
    2. Fig 1: Locating Insulator Nuts
    GM890990Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  2. Tighten the 2 brake pressure modulator assembly insulator nuts (1).

    Tighten:  Tighten the nuts to 8 N.m (71 lb in).

    3. Fig 2: View Of Wheel & Master Cylinder Brake Pipes
    GM890985Courtesy of GENERAL MOTORS CORP.
  3. Remove the caps from the master cylinder brake pipe ends.
  4. Remove the plugs from the master cylinder ports on the modulator assembly.
  5. Connect the master cylinder brake pipes (2) to the modulator assembly, in the same location as removed.
  6. Tighten the brake pipe fittings at the brake pressure modulator valve (BPMV).

    Tighten: 

    • Tighten the fittings, first design, ISO flare to 19 N.m (14 lb ft).
    • Tighten the fittings, second design, double inverted flare to 18 N.m (13 lb ft).

  7. Remove the caps from the caliper and wheel cylinder brake pipe ends.
  8. Remove the plugs from the caliper and wheel cylinder ports on the modulator assembly.
  9. Connect the caliper and wheel cylinder brake pipes (1) to the modulator assembly, in the same location as removed.
  10. Tighten the brake pipe fittings at the BPMV.

    Tighten: 

    • Tighten the fittings, first design, ISO flare to 19 N.m (14 lb ft).
    • Tighten the fittings, second design, double inverted flare to 18 N.m (13 lb ft).

    11. Fig 3: View Of EBCM Electrical Connector
    GM890987Courtesy of GENERAL MOTORS CORP.
  11. Connect the electrical connector to the EBCM.
  12. Bleed the hydraulic brake system. Refer to MANUAL BLEEDING or PRESSURE BLEEDING .
  13. Turn the ignition switch to the ON position. DO NOT start engine.
  14. Perform the Diagnostic System Check - ABS .
  15. Observe the feel of the brake pedal after performing the diagnostic system check. If the pedal now feels spongy, air may have been in the secondary circuit of the brake modulator assembly, which may have been introduced into the primary circuit. If the pedal feels spongy, perform the ABS Automated Bleed Procedure .
  16. Remove the shop towel and discard into an approved container.
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