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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISBRAKESANTILOCK BRAKE SYSTEM WITH TRACTION CONTROL SYSTEM & STABILITY CONTROL SYSTEMREPAIR INSTRUCTIONSBRAKE PRESSURE MODULATOR VALVE PRE-CHARGE PUMP REPLACEMENTINSTALLATION PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Installation Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Installation Procedure
    Fig 1: Brake Fluid Outlet Pipe
    GM1372859Courtesy of GENERAL MOTORS CORP.
  1. Install the PCP (2) into the vehicle.
    2. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the PCP front and side mounting bracket bolts (1, 3).

    Tighten:  Tighten the bolts to 20 N.m (15 lb ft).

  3. Connect the engine wiring harness to the PCP bracket.
  4. Connect the PCP electrical connector (4) to the vehicle connector harness.
  5. Remove the cap or plug from the outlet pipe and install the outlet pipe to the PCP (5).

    Tighten:  Tighten the brake fluid outlet pipe nut to 25 N.m (18 lb ft).

    6. Fig 2: Master Cylinder Components
    GM1372862Courtesy of GENERAL MOTORS CORP.
  6. Install the inlet hose (4) and clamp (3) to the PCP (2).
  7. Remove the crimping tool from the inlet hose.
  8. Install the inner fender splash shield.
  9. Install the left front wheel and tire. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  11. Fill the master cylinder reservoir. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.
  12. Using a scan tool, perform a PCP bleed procedure. Refer to ABS Automated Bleed Procedure (W/JL4)  or ABS Automated Bleed Procedure (w/o JL4) .
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.