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ABS hydraulic unit - removal and refitting
Braking system / ABS hydraulic unit - removal and refitting


Note: If any part of the ABS hydraulic unit is defective, it must be renewed as an assembly.

Apart from the relay box (Section 22), individual spare parts are not available.

Removal
1 Remove both pressure-control relief valves as described in Section 19.

2 Identify the location of the remaining brake hydraulic pipes on the ABS hydraulic unit, then unscrew the union nuts and pull out the pipes. Carefully bend the pipes away from the hydraulic unit, to allow the unit to be removed.

3 Disconnect the multi-plugs from the hydraulic unit. To disconnect the main 22-pin multi-plug, push the locktab, then swivel the multi-plug outwards and unhook it.

Right-hand drive models
4 Have an assistant hold the brake pedal depressed, then extract the spring clip and remove the clevis pin securing the servo unit pushrod to the pedal cross-link arm.

5 Remove the vacuum servo unit from the engine compartment.

Left-hand drive models
6 Unscrew the nut securing the pedal trunnion to the servo unit pushrod inside the passenger compartment. The nut is located near the top of the pedal, and is accessible through an access hole. For improved access, remove the lower facia panel first.

7 Remove the vacuum servo unit, together with the pushrod, from the engine compartment. Take care not to damage the rubber grommet in the bulkhead.

All models
8 Unscrew the pump mounting nut.

9 Raise the left-hand side of the ABS hydraulic unit, then swivel the unit out of the right-hand mounting. Take care not to lose the bracket studs and insulator ring.

Refitting
10 Locate the insulator ring on the pump end, and fit the stud cap to the insulator ring.

11 Lower the ABS hydraulic unit into position, right-hand end first.

12 Fit the right-hand bracket studs onto the insulators.

13 Lower the left-hand end of the ABS hydraulic unit onto the bracket, then fit and tighten the pump mounting nut.

Left-hand drive models
14 Locate the vacuum servo unit and pushrod on the bulkhead bracket, taking care not to damage the rubber grommet.

15 Insert the pushrod in the pedal trunnion, and tighten the nut.

16 Refit the lower facia panel if it was removed.

Right-hand drive models
17 Locate the vacuum servo unit and pushrod on the bulkhead bracket.

18 Refit the clevis pin and spring clip securing the servo unit pushrod to the pedal cross-link arm.

All models
19 Reconnect the multi-plugs to the hydraulic unit.

20 Reconnect the brake pipes to the hydraulic unit, and tighten the union nuts.

21 Refit both pressure-control relief valves, with reference to Section 20.


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