Replacing the ABS hydraulic modulator and control module

WARNING: This page is about a different car, the 2004 Volvo S40, 2003 Volvo S40, 2002 Volvo S40, 2001 Volvo S40, and 2000 Volvo S40. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: For service work, the modulator is supplied with the control module. The secondary modulator circuit is equipped with brake fluid, so that the brake system can be bled in the normal way after assembly.

Preparations

Remove

the engine coolant hose (hoses) from the clamps and the clamp above the control module.
the right headlamp (only cars with Air Conditioning (A/C)), see Replacing the headlamp assembly .

Put rags under the modulator to prevent brake fluid spilling onto painted surfaces.

Switch off the switch.

Removing the kit with the control module

Fig 1: Identifying Control Module Connector, Brake Pipes And Centrally Placed Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect the brake pipes on the modulator. Collect the brake fluid.

Remove the bracket for the brake pipe from the inside of the fender.

Remove the two bolts and the support at the front. Remove the rubber components.

Twist the control module from the inside of the fender. Disconnect the connector.

Remove the brake pipes from the modulator.

Place the power steering pipes to one side.

Carefully bend the brake pipes upwards so that they are out of the way.

Remove the rubber from the centrally placed bolt.

Plug the brake pipes.

Installing the modulator with the control module

Remove the plugs from the brake pipes. Install the modulator and the control module.

Fig 2: Identifying Control Module Connector, Brake Pipes And Centrally Placed Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install

the control module connector.
the rubber on the centrally placed bolt.
the modulator on the support inside the fender.
the brake pipes (without putting them under strain). Hand tighten the brake pipes.
the support with the rubber components on the control module.

Center and tighten the bolts to 25 Nm.

NOTE: Connect the modulator ground lead to the rear bolt.

Secure the brake pipes to the front fender liner.

Locate the engine coolant hose (hoses) and the power steering hose correctly.

Connect the brake lines to the system.

Tighten to 14 Nm. The brake lines must not touch each other.

Conclusion

Bleeding the brake system. See Bleeding brake system .

Wash away any spilled brake fluid with warm water and car shampoo.

Checking the function of the ABS system

Read off the diagnostic trouble codes (DTCs).

Test drive the car. Check that the ABS warning lamp goes out.

Read off and check whether any diagnostic trouble codes (DTCs) have been stored.