Abs

Document ID: 2022003
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2009 Chevrolet Cobalt
| Cobalt, G5 (VIN A) Service Manual | Brakes | Antilock Brake System | Specifications | Document ID: 2022003
Fastener Tightening Specifications

Specification Application Brake Pipe Fitting Brake Pressure Modulator Valve (BPMV) to Mounting Bracket Bolt BPMV Mounting Bracket Bolt BPMV Mounting Pin Electronic Brake Control Module (EBCM) Bolt (With JL4) EBCM Bolt (Without JL4) Engine Control Module (ECM) Bracket and BPMV Bracket Mounting Bolt Yaw Rate Sensor Nut Metric 19 Nm 11 Nm 25 Nm 10 Nm 3 Nm 2.3 Nm 10 Nm English 14 lb ft 97 lb in 18 lb ft 89 lb in 27 lb in 20 lb in 89 lb in
12 Nm 106 lb in
2010 General Motors Corporation. All rights reserved.
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| Cobalt, G5 (VIN A) Service Manual | Brakes | Antilock Brake System | Repair Instructions | Document ID: 2161651
Antilock Brake System Automated Bleed Procedure

Warning: Refer to Brake Fluid Irritant Warning in the Preface section. Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution in the Preface section. Note: Before performing the ABS Automated Bleed Procedure, first perform a manual or pressure bleed of the base brake system. Refer to Hydraulic Brake System Bleeding. The automated bleed procedure is recommended when one of the following conditions exist: Base brake system bleeding does not achieve the desired pedal height or feel Extreme loss of brake fluid has occurred Air ingestion is suspected in the secondary circuits of the brake modulator assembly The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run the pump in order to purge any air from the secondary circuits. These circuits are normally closed off, and are only opened during system initialization at vehicle start up and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped in these circuits to flow out toward the brake corners.
Performing the Automated Bleed Procedure

Caution: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove all four tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation. 3. Inspect the brake system for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes. Repair or replace components as needed. 4. Lower the vehicle. 5. Inspect the battery state of charge. Refer to Battery Inspection/Test. 6. Install a scan tool. 7. Turn the ignition ON, with the engine OFF. 8. With the scan tool, establish communications with the ABS system. Select Special Functions. Select Automated Bleed from the Special Functions menu. 9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 10. Following the directions given on the scan tool, pressure bleed the base brake system. Refer to Hydraulic Brake System Bleeding. 11. Follow the scan tool directions until the desired brake pedal height is achieved. 12. If the bleed procedure is aborted, a malfunction exists. Perform the following steps before resuming the bleed procedure: If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List - Vehicle , and diagnose the appropriate DTC. If the brake pedal feels spongy, perform the conventional brake bleed procedure again. Refer to Hydraulic Brake System Bleeding. 13. When the desired pedal2010 General Motors Corporation. Allbrakereserved. inspect for firmness. height is achieved, press the rights pedal to
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14. 15. 16. 17. 18.
Lower the vehicle. Remove the scan tool. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation. Inspect the brake fluid level. Refer to Master Cylinder Reservoir Filling. Road test the vehicle while inspecting that the pedal remains high and firm.
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Steering Angle Sensor Centering

The steering angle sensor does not require centering often. Centering of the steering angle sensor might be required after certain service procedures are performed. Some of these procedures are as follows: Steering gear replacement Steering column replacement Steering angle sensor replacement Intermediate shaft replacement Electronic Brake Control Module (EBCM) programming or replacement Brake Pressure Modulator Valve Replacement Collision or other physical damage 1. Center the steering wheel with the wheels facing forward. 2. With a scan tool, perform the special functions steering position sensor calibration and follow the on screen instructions.
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Electronic Brake Control Module Replacement (Without JL4)
Callout
Component Name
Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM.
Preliminary Procedures
1. Turn the ignition switch to the OFF position. 2. Remove the cover from the engine control module (ECM) and transmission control module (TCM). 3. Clean the electronic brake control module (EBCM) to brake pressure modulator valve (BPMV) area of any accumulated dirt and foreign material. Electronic Brake Control Module (EBCM) Electrical Connector 1
Procedure
Lift the EBCM slide lock tabs on top of the electrical connector to release the connector from the module. EBCM to Brake Pressure Modulator Corporation. All rights reserved. 2010 General Motors Valve (BPMV) Retaining Bolt (Qty: 3)
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Caution: Refer to Fastener Caution in the Preface section. 2 Tighten 2.3 Nm (20 lb in) Electronic Brake Control Module
Procedure
3 1. Separate the EBCM from the BPMV by carefully pulling apart. Do not pry apart. 2. Clean the sealing surface of the BPMV with denatured alcohol and a clean shop cloth. 3. If installing a new EBCM, program the EBCM. Refer to Electronic Brake Control Module Programming and Setup. 4. Refer to Control Module References for programming and setup information. EBCM O-Ring Seal (Qty: 8) 4
Procedure
If installing a new EBCM, install new O-ring seals.
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Electronic Brake Control Module Replacement (With JL4)

Removal Procedure
1. Turn the ignition switch to the OFF position. 2. Remove the cover from the engine control module (ECM) and transmission control module (TCM). 3. Clean the electronic brake control module (EBCM) to brake pressure modulator valve (BPMV) area of any accumulated dirt and foreign material. 4. Disconnect the electrical connector from the EBCM. 5. Remove the EBCM bolts (1).
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6. Separate the EBCM (1) from the BPMV by carefully pulling apart. Do not pry the components apart.
7. Remove the 12 EBCM O-ring seals (1). 8. If installing a new EBCM, discard the O-ring seals.
Installation Procedure
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1. Install the 12 EBCM O-ring seals (1). 2. If installing a new EBCM, install new O-ring seals.
3. Carefully install the EBCM (1) to the BPMV. Caution: Refer to Fastener Caution in the Preface section.
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4. Install the EBCM bolts (1). Tighten Tighten the bolts to 3 Nm (27 lb in). 5. Connect the electrical connector to the EBCM. 6. Install the cover to the ECM and TCM. 7. If a new EBCM is being installed, program the EBCM. Refer to Electronic Brake Control Module Programming and Setup. 8. Refer to Control Module References for programming and setup information.
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Brake Pressure Modulator Valve Replacement (Without JL4)
Callout
Component Name
Warning: Refer to Brake Fluid Irritant Warning in the Preface section. Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM.
1. Turn the ignition switch to the OFF position. 2. Remove the cover from the engine control module (ECM) and the transmission control module (TCM). 3. Clean the electronic brake control module (EBCM) to brake pressure modulator valve (BPMV) area and the brake pipe fitting areas of any accumulated dirt and foreign material.
Electronic Brake Control Module (EBCM) Electrical Connector
Procedure
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Lift the slide lock tabs to release the electrical connector from the EBCM. Electronic Brake Control Module (EBCM) 2
Procedure
If installing a new BPMV, remove the EBCM. Refer to Electronic Brake Control Module Replacement. Brake Pipe Fitting (Qty: 6) Caution: Refer to Fastener Caution in the Preface section. Tighten 19 Nm (14 lb ft)
Procedure
1. Note the location of the brake pipes before removal to aid installation. 2. Cap the brake pipe ends and plug the pipe ports on the BPMV to prevent brake fluid loss and contamination. Brake Pressure Modulator Valve (BPMV) to Mounting Bracket Bolt 4 Tighten 11 Nm (97 lb in) Brake Pressure Modulator Valve (BPMV) Bracket Insulator (Qty: 3) Tip Inspect the insulators and replace if necessary. Do not remove the BPMV mounting pins unless it is necessary to aid in releasing the modulator assembly from the bracket. Brake Pressure Modulator Valve (BPMV)
Procedure
1. Do not pry against the accumulator covers on the underside of the brake pressure modulator assembly to release the mounting pins from the bracket insulators. 2. If installing a new BPMV, install new EBCM to BPMV O-ring seals. 3. A new BPMV comes with both the primary and secondary circuits pre-filled with brake fluid. If the ignition key has not been cycled after installation, only a base brake bleed is necessary. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding. 4. Perform the Diagnostic System Check - Vehicle. 5. Observe the brake pedal feel after performing the diagnostic system check. If the pedal now feels spongy, air may have been in or may have been introduced into the secondary hydraulic circuit of the brake modulator which then may have been introduced into the primary circuit. If the brake pedal feels spongy, perform the Antilock Brake System
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Automated Bleed Procedure.
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Brake Pressure Modulator Valve Replacement (With JL4, LNF)

Removal Procedure
1. Turn the ignition switch to the OFF position. 2. Clean the brake pressure modulator valve (BPMV) brake pipe fitting area of any accumulated dirt and foreign material. 3. Disconnect the electronic brake control module (EBCM) electrical connector. 4. Disconnect the LR brake pipe fitting (1) from the BPMV. Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. 5. Disconnect the RR brake pipe fitting (2) from the BPMV. Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination.
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6. Disconnect the LF brake pipe fitting (1) from the BPMV. Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. 7. Disconnect the RF brake pipe fitting (2) from the BPMV. Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination.
8. Disconnect the master cylinder primary brake pipe fitting (1) from the BPMV.
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Cap the brake pipe fitting and plug the BPMV inlet port to prevent brake fluid loss and contamination. 9. Disconnect the master cylinder secondary brake pipe fitting (2) from the BPMV. Cap the brake pipe fitting and plug the BPMV inlet port to prevent brake fluid loss and contamination.
10. Remove the BPMV bolt (1).
11. Carefully remove the brake control module assembly (1) from the BPMV bracket insulators by pulling straight upward.
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Do not pry against the accumulator covers on the underside of the brake modulator assembly to release the mounting pins from the bracket insulators. 12. If installing a new BPMV, remove the EBCM. Refer to Electronic Brake Control Module Replacement.
1. If installing a new BPMV, install the EBCM. Refer to Electronic Brake Control Module Replacement.
2. Install the BPMV (1) to the BPMV bracket until the mounting pins are fully inserted in the bracket insulators. Caution: Refer to Fastener Caution in the Preface section.
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3. Install the BPMV bolt (1). Tighten Tighten the bolt to 11 Nm (97 lb in).
4. Connect the master cylinder primary brake pipe fitting (1) to the BPMV. Tighten Tighten the fitting to 19 Nm (14 lb ft). 5. Connect the master cylinder secondary brake pipe fitting (2) to the BPMV.
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Tighten Tighten the fitting to 19 Nm (14 lb ft).
6. Connect the LF brake pipe fitting (1) to the BPMV. Tighten Tighten the fitting to 19 Nm (14 lb ft). 7. Connect the RF brake pipe fitting (2) to the BPMV. Tighten Tighten the fitting to 19 Nm (14 lb ft).
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8. Connect the LR brake pipe fitting (1) to the BPMV. Tighten Tighten the fitting to 19 Nm (14 lb ft). 9. Connect the RR brake pipe fitting (2) to the BPMV. Tighten Tighten the fitting to 19 Nm (14 lb ft). 10. 11. 12. 13. 14. Connect the EBCM electrical connector. Program the EBCM. Refer to Electronic Brake Control Module Programming and Setup. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding. Perform the Diagnostic System Check - Vehicle. Observe the brake pedal feel after performing the diagnostic system check. If the pedal now feels spongy, air may have been in the secondary hydraulic circuit of the brake modulator which may have been introduced into the primary circuit. If the pedal feels spongy, perform the Antilock Brake System Automated Bleed Procedure.
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Brake Pressure Modulator Valve Replacement (With JL4)

Removal Procedure
1. Turn the ignition switch to the OFF position. 2. Remove the cover from the engine control module (ECM) and transmission control module (TCM), if equipped. 3. Clean the electronic brake control module (EBCM) to brake pressure modulator valve (BPMV) area of any accumulated dirt and foreign material. 4. Disconnect the electrical connector from the EBCM. 5. Disconnect the LR brake pipe fitting (1) from the BPMV. Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. 6. Disconnect the RR brake pipe fitting (2) from the BPMV. Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination.
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7. Disconnect the LF brake pipe fitting (1) from the BPMV. Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. 8. Disconnect the RF brake pipe fitting (2) from the BPMV. Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination.
9. Disconnect the master cylinder primary brake pipe fitting (1) from the BPMV.
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Cap the brake pipe fitting and plug the BPMV inlet port to prevent brake fluid loss and contamination. 10. Disconnect the master cylinder secondary brake pipe fitting (2) from the BPMV. Cap the brake pipe fitting and plug the BPMV inlet port to prevent brake fluid loss and contamination.
11. Remove the BPMV bolt (1).
12. Carefully remove the BPMV (1) from the BPMV bracket insulators by pulling straight upward. Do not pry against the accumulator covers on the underside of the brake modulator assembly
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to release the mounting pins from the bracket insulators. 13. If installing a new BPMV, remove the EBCM. Refer to Electronic Brake Control Module Replacement.
1. If installing a new BPMV, install the EBCM. Refer to Electronic Brake Control Module Replacement.
2. Install the BPMV (1) to the BPMV bracket until the mounting pins are fully inserted in the bracket insulators. 3. If installing a new EBCM, install new O-ring seals. Caution: Refer to Fastener Caution in the Preface section.
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4. Install the BPMV bolt (1). Tighten Tighten the bolt to 11 Nm (97 lb in).
5. Connect the master cylinder primary brake pipe fitting (1) to the BPMV. Tighten Tighten the fitting to 19 Nm (14 lb ft). 6. Connect the master cylinder secondary brake pipe fitting (2) to the BPMV.
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Tighten Tighten the fitting to 19 Nm (14 lb ft).
7. Connect the LF brake pipe fitting (1) to the BPMV. Tighten Tighten the fitting to 19 Nm (14 lb ft). 8. Connect the RF brake pipe fitting (2) to the BPMV. Tighten Tighten the fitting to 19 Nm (14 lb ft).
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9. Connect the LR brake pipe fitting (1) to the BPMV. Tighten Tighten the fitting to 19 Nm (14 lb ft). 10. Connect the RR brake pipe fitting (2) to the BPMV. Tighten Tighten the fitting to 19 Nm (14 lb ft). 11. 12. 13. 14. 15. Connect the electrical connector to the EBCM. Install the cover to the ECM and TCM, if removed. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding. Perform the Diagnostic System Check - Vehicle. Observe the brake pedal feel after performing the diagnostic system check. If the pedal now feels spongy, air may have been in the secondary hydraulic circuit of the brake modulator which may have been introduced into the primary circuit. If the pedal feels spongy, perform the Antilock Brake System Automated Bleed Procedure.
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Brake Pressure Modulator Valve Bracket Replacement (With JL4)

Removal Procedure
1. Turn the ignition switch to the OFF position. 2. Remove the cover from the engine control module (ECM) and transmission control module (TCM), if equipped. 3. Release the brake pipes from the retainer on the wheelhouse panel. 4. Remove the brake pressure modulator valve (BPMV) bolt (1).
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5. Remove the BPMV (1) from the bracket by pulling straight upward. Do not pry against the accumulator covers on the underside of the brake modulator assembly to release the mounting pins from the bracket insulators. 6. Support the BPMV with heavy mechanics wire or equivalent.
7. Remove the 3 BPMV bracket bolts (1). 8. Remove the BPMV bracket.
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9. Remove the BPMV bracket insulators (1).
1. Install the BPMV bracket insulators (1).
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2. Install the BPMV bracket. Caution: Refer to Fastener Caution in the Preface section. 3. Install the 3 BPMV bracket bolts (1). Tighten Tighten the bolts to 25 Nm (18 lb ft).
4. Install the BPMV (1) to the bracket by pressing the BPMV mounting pins into the bracket insulators until fully seated.
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5. Install the BPMV bolt (1). Tighten Tighten the bolt to 11 Nm (97 lb in). 6. Install the brake pipes to the retainer on the wheelhouse panel. 7. Install the cover to the ECM and TCM, if removed.
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Brake Pressure Modulator Valve Bracket Replacement (Without JL4)
Callout
Component Name
1. Turn the ignition switch to the OFF position. 2. Remove the cover from the engine control module (ECM) and the transmission control module (TCM). Brake Pressure Modulator Valve (BPMV) to Mounting Bracket Bolt 1 Caution: Refer to Fastener Caution in the Preface section. Tighten 11 Nm (97 lb in) Brake Pressure Modulator Valve (BPMV) Mounting Pin (Qty: 2)
Procedure
1. Do not pry against the accumulator covers on the underside of the brake pressure modulator assembly to release the mounting pins from the bracket insulators. 2010 General Motors Corporation. All rights reserved.
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2. Do not remove the mounting pins unless it is necessary to aid in releasing the modulator assembly from the bracket. 3. Position and support the modulator assembly to aid in bracket removal. Tighten 10 Nm (89 lb in) Brake Pressure Modulator Valve (BPMV) Bracket Insulator (Qty: 3) 3 Tip Inspect the insulators and replace if necessary. Engine Control Module (ECM) Bracket and BPMV Mounting Bolt (Qty: 2) 4 Tighten 12 Nm (106 lb in) BPMV Mounting Bracket Bolt 5 Tighten 25 Nm (18 lb ft) BPMV Mounting Bracket
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Electronic Traction Control Switch Replacement
Callout
Component Name
Caution: Refer to Fastener Caution in the Preface section.
1. Remove the steering column opening filler assembly. Refer to Steering Column Opening Filler Replacement. 2. Tilt the steering wheel up. 1 Electronic Traction Control Switch Clip (Qty: 2) Electronic Traction Control Switch Assembly
Procedure
2 1. Release the switch assembly by pulling away from the instrument panel retainer. 2. Disconnect the electrical connector.
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Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement

Removal Procedure
1. Turn OFF the ignition. 2. Remove the right front seat. Refer to Front Seat Replacement - Bucket. 3. Remove the right side front carpet retainer. Refer to Front Side Door Opening Floor Carpet Retainer Replacement. 4. Carefully lift the floor carpet to access the yaw rate sensor. 5. Disconnect the yaw rate sensor electrical connector. 6. Remove the yaw rate sensor nuts (1).
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7. Remove the yaw rate sensor (1).
1. Install the yaw rate sensor (1). Caution: Refer to Fastener Caution in the Preface section.
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2. Install the yaw rate sensor nuts (1). Tighten Tighten the nuts to 10 Nm (89 lb in). 3. Connect the yaw rate sensor electrical connector. 4. Carefully position the floor carpet to the vehicle floor. 5. Install the right side front carpet retainer. Refer to Front Side Door Opening Floor Carpet Retainer Replacement. 6. Install the right front seat. Refer to Front Seat Replacement - Bucket. 7. Install a scan tool. 8. Using the special functions menu on the scan tool, perform the steering angle sensor calibration. Refer to Control Module References. 9. Perform the Diagnostic System Check - Vehicle.

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Document ID: 2022003

2009 Chevrolet Cobalt

Fastener Tightening Specifications

2010 General Motors Corporation. All rights reserved.

Document ID: 2161651

2009 Chevrolet Cobalt

Antilock Brake System Automated Bleed Procedure

Performing the Automated Bleed Procedure

Document ID: 2161651

14. 15. 16. 17. 18.

Document ID: 2184241

2009 Chevrolet Cobalt

Steering Angle Sensor Centering

2010 General Motors Corporation. All rights reserved.

Document ID: 2175706

2009 Chevrolet Cobalt

Electronic Brake Control Module Replacement (Without JL4)

Document ID: 2175706

Document ID: 2175704

2009 Chevrolet Cobalt

Electronic Brake Control Module Replacement (With JL4)

2010 General Motors Corporation. All rights reserved.

Document ID: 2175704

Document ID: 2175704

Document ID: 2175704

Document ID: 2175711

2009 Chevrolet Cobalt

Brake Pressure Modulator Valve Replacement (Without JL4)

Electronic Brake Control Module (EBCM) Electrical Connector

2010 General Motors Corporation. All rights reserved.

Document ID: 2175711

Document ID: 2175711

Automated Bleed Procedure.

Document ID: 2175710

2009 Chevrolet Cobalt

Brake Pressure Modulator Valve Replacement (With JL4, LNF)

2010 General Motors Corporation. All rights reserved.

Document ID: 2175710

Document ID: 2175710

10. Remove the BPMV bolt (1).

Document ID: 2175710

Document ID: 2175710

Document ID: 2175710

Tighten Tighten the fitting to 19 Nm (14 lb ft).

Document ID: 2175710

Document ID: 2175709

2009 Chevrolet Cobalt

Brake Pressure Modulator Valve Replacement (With JL4)

2010 General Motors Corporation. All rights reserved.

Document ID: 2175709

Document ID: 2175709

11. Remove the BPMV bolt (1).

Document ID: 2175709

Document ID: 2175709

Document ID: 2175709

Tighten Tighten the fitting to 19 Nm (14 lb ft).

Document ID: 2175709

Document ID: 2175714

2009 Chevrolet Cobalt

Brake Pressure Modulator Valve Bracket Replacement (With JL4)

2010 General Motors Corporation. All rights reserved.

Document ID: 2175714

Document ID: 2175714