Attachment III - Technical Information

OVERVIEW

This program involves installing a heat shield onto the ABS Module, replacing a fuse and attaching labels in the Owner's Guide and on the power distribution box (PDB) cover identifying the revised fuse amperage rating for the ABS Module circuit. For vehicles equipped with Hydro-boost, the ABS module must be removed from the HCU in order to install the heat shield.

FUSE REPLACEMENT AND LABEL INSTALLATION - ALL AFFECTED VEHICLES

1. Open the hood and remove the PDB cover.

2. Locate and remove the 4 wheel anti-lock brake system (4WABS) 60 amp (blue) fuse.





NOTE:
On certain models, the PDB may be mounted opposite of how it is shown in Figure 1. Be sure to identify and replace the correct fuse.

NOTE:
Although the 2003 and 2004 PDB appear to be identical, the fuse locations have different numbers. See Figure 1.

3. Install a new 30-amp (green) fuse in place of the original 60-amp (blue) fuse.

4. Install the PDB cover.





5. NOTE: Two (2) sheets of labels are provided in the service kit. One sheet is for 2003 model year vehicles and one for 2004 model year vehicles. Use the appropriate model year sheet and discard the remaining sheet. See Figure 2.

Each sheet contains two (2) labels:

^ One (1) label for the top of the Power Distribution Box (PDB). (WARNING LABEL) One (1) label to install in the Owner Guide. (30A** LABEL)





Clean the PDB cover and install the supplied PDB cover label. See Figure 3.





6. Locate the vehicle Owner's Guide. In the FUSES AND RELAYS section under Roadside Emergencies, locate the PDB fuse identification chart.

7. Apply the supplied "30A **" label over the 60A** designation for the 4WABS module system fuse. See the samples below. Return the Owner's Guide to its original location.

8. Go to HEAT SHIELD INSTALLATION.

^ Be sure to follow the correct procedure based on whether or not the vehicle has Hydro-boost brakes.

HEAT SHIELD INSTALLATION - VEHICLES WITHOUT HYDRO-BOOST

1. If required for access to install the heat shield, disconnect the speed control deactivation switch located at the bottom of the master cylinder.

2. Install the ABS Module heat shield as follows:

a) Clean the top of the ABS module with the alcohol pad provided in the service kit.

b) Hold the radiator coolant reservoir hose out of the way.





c) Position the heat shield so it will fit securely against the connector side of the module, set the retaining hooks under the lip of the rear side of the module, then rotate the shield downward to snap it into place. See Figure 4.

3. If disconnected, reconnect the speed control deactivation switch.

4. Close the hood.

HEAT SHIELD INSTALLATION - VEHICLES WITH HYDRO-BOOST

NOTE:
To install the heat shield on vehicles with Hydro-boost, the ABS module must be removed from the HCU due to lack of clearance between the module and the brake master cylinder.

1. Remove the coolant recovery reservoir retaining screws.

2. If required for access to the ABS module, remove the air cleaner assembly.





3. Disconnect the module wire harness connector by releasing the lock tab and pulling the connector from the module. See Figure 5.





4. Remove the four (4) Torx head screws securing the ABS module to the HCU. See Figure 6.





5. Lift the module slightly and position it so you can access and disconnect the ABS pump motor connector. Then disconnect the pump motor and remove the module from the vehicle. See Figure 7.

6. Install the ABS Module heat shield as follows:

a) Clean the top of the ABS module with the alcohol pad provided in the service kit.





b) Position the heat shield so it will fit securely against the connector side of the module, set the retaining hooks under the lip of the rear side of the module, then rotate the shield downward to snap it into place. See Figure 8.

7. Position the module near the HCU and connect the ABS pump motor connector. See Figure 7.

8. Carefully position the module onto the HCU and install the four (4) screws. Tighten screws to 4 Nm (35 lb-in). See Figure 6.

9. Connect the module wire harness connector and engage the lock tab.

10. Position the coolant recovery reservoir and install the retaining screws.

11. If removed, reinstall the air cleaner assembly.

12. Close the hood.