Contents: Removal ⬇ Installation ⬇
Note: Read Chapter 2 before you start work.
Removal
1. Disconnect the negative cable from the battery.
2. Remove the brake fluid reservoir cap, cover its filler neck with a piece of polyethylene and secure it with a rubber band or reinstall the cap. This will reduce fluid loss during the next procedure.
3. Loosen the mounting screw and remove the plastic cover from the hydraulic modulator.
4. Unscrew the two clamp screws and remove the modulator wiring harness clamp (see illustration).
5. Disconnect the modulator wiring connector by prying it out of its socket with a screwdriver if necessary.
6. Loosen the brake pipe union nuts and disconnect the pipes from the modulator. Be prepared for fluid to escape and plug any openings to prevent dirt from getting in and further fluid loss. Move the pipes away from the modulator, being careful not to deform them.
7. Unscrew the three modulator mounting nuts (see illustration), then tilt the modulator slightly and lift it off the bracket enough to gain access to the ground loop mounting nut located on the front bottom edge of the modulator.
8. Loosen the mounting nut and disconnect the ground cable, then remove the modulator from the engine compartment, being careful not to spill brake fluid on the painted parts of the body.
9. When replacing the modulator, remove two relays from the old unit and move them to the new one. Do not try to disassemble the modulator.
Installation
10. Before installing the modulator, make sure that the bolts securing its bracket to the body panel are tightened securely and that the rubber pads of the modulator are in good condition. Replace the rubber pads if necessary.
11. Perform installation in reverse order, paying attention to the following.
12. Do not forget to install the ground loop before installing the modulator on the mounting bracket.
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13. Finally, remove the polyethylene from the filler neck of the brake hydraulic system replenishment tank and bleed the entire brake system as described in Chapter 3.
14. Check that the ABS warning lamp goes out when the engine is first started after the modulator has been removed. Have the ABS system tested by an Opel dealer at the earliest opportunity using the appropriate special equipment.
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