NHTSA ID Number: 10245844
Manufacturer Communication Number: 12189
TSB/Document Date: 2023-12-04
Summary
Long Brake Pedal Travel and/or Reduced Brake Performance
Bulletin No.: 12189
Date: November 2012
Program Bulletin
CUSTOMER SATISFACTION PROGRAM
SUBJECT:
Long Brake Pedal Travel and/or Reduced Brake Performance
MODELS:
2007 Chevrolet
Optra
2009-2010 Chevrolet Aveo
2009 Pontiac G3, Wave
Equipped with ABS Brakes (JM4/JL9)
THIS PROGRAM IS IN EFFECT UNTIL NOVEMBER 30, 2014.
CONDITION
Certain 2007 model year Chevrolet Optra vehicles, 2009 and 2010 model year Chevrolet Aveo
vehicles, and 2009 model year Pontiac G3 and Wave vehicles, equipped with ABS brakes
(JM4/JL9), may contain brake fluid that does not inhibit corrosion in the zinc plating on the antilock brake system (ABS) module valve armature. Corrosion may lead to a gel build up on the
sides of the valve, which could affect the closing motion of the valve. This could result in longer
brake pedal travel and/or reduced brake performance.
CORRECTION
Dealers are to inspect the ABS module and, if necessary, replace the module. Dealers are to
also change the brake fluid and provide a supplement to the Owner Manual that instructs
customers to use only GM recommended brake fluid.
VEHICLES INVOLVED
All involved vehicles are identified by Vehicle Identification Number on the Investigate Vehicle
History screen in GM Global Warranty Management system. Dealership service personnel
should always check this site to confirm vehicle involvement prior to beginning any required
inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not
all similar vehicles may be involved regardless of description or option content.
Page 2
November 2012
Bulletin No.: 12189
For dealers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and
will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have
a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle
Registration Records. The use of such motor vehicle registration data for any purpose other
than follow-up necessary to complete this program is a violation of law in several
states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
PART INFORMATION
Due to the small number of vehicles expected to require replacement of the ABS module,
modules can only be ordered from the Product Quality Center (PQC) when the inspection
determines that it is necessary to replace the module. Orders placed without PQC
approval will automatically cancel.
Brake fluid and engine coolant, if required, are to be obtained from General Motors Customer
Care and Aftersales (GMCC&A). Please refer to your “involved vehicles listing” before ordering
parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an
emergency situation, parts should be ordered on a CSO = Customer Special Order.
Part Number
95241314
Description
MODULE KIT, ELEK BRK CONT
(Aveo, G3, Wave)
MODULE KIT, ELEK BRK CONT
(Optra)
BRAKE FLUID
Quantity/Vehicle
1
FLUID, EXTENDED LIFE ENG COOLANT
(Optra)
1
95242007
19299818 – US
19299819 - CN
10953031
1
4
SERVICE PROCEDURE
Tech 2 Tool Update
Ensure that your Tech 2 is updated with software version 32.005 or higher. You can obtain this
in the Software Download section of TIS2Web.
ABS Module Inspection
1.
Park the vehicle on a flat, level surface.
2.
Apply the parking brake.
3.
Connect scan tool.
Page 3
November 2012
2911409
4.
Select “F1: ABS Check” in Special Functions.
5.
Start ABS valve check.
6.
The Waiting for Data screen will appear.
Bulletin No.: 12189
Page 4
November 2012
Bulletin No.: 12189
While this screen is displayed, the pump motor is running (1sec).
7.
The “Procedure in Progress” message will appear on the ABS Check screen.
When the Tech 2 screen is prompted to “Apply and Hold the Brake Pedal,” the technician should apply
and hold heavy brake force during ABS Check.
①
②
With the valve open, the pedal will drop for 2 seconds. With the motor pumping, the pedal will push
back for 3 seconds.
Note: The Tech 2 test sequence is left front, right front, left rear and right rear during steps 8
through 23.
If the ABS/ESC module test passes all 4 procedures (4 pedal drops and 4 push backs are
“YES”), replace the brake fluid with Delco Supreme 11 Brake Fluid (P/N 19299818 USA, P/N
19299819 Canada). Flush the brake system. Refer to Brake Valve Cycling in this bulletin and
proceed to Brake Valve Cycling on the Tech 2.
If any of the answers are “NO”, replace the ABS/ESC HCU and brake fluid with Delco
Supreme 11 Brake Fluid (P/N 19299818 USA, P/N 19299819 Canada). Refer to Chevrolet
Page 5
November 2012
Bulletin No.: 12189
Optra Brake Pressure Modulator Replacement or Chevrolet Aveo, Pontiac G3 and Pontiac
Wave Brake Pressure Modulator Replacement in this bulletin.
8.
Apply and hold brake pedal.
9.
Answer the question on the ABS Check screen.
If the answer is yes, proceed to the next step.
If the answer is no, proceed to Chevrolet Optra Brake Modulator Replacement or
Chevrolet Aveo, Pontiac G3 and Pontiac Wave Brake Modulator Replacement in this
bulletin.
10. Answer the question on the ABS Check screen.
If the answer is yes, proceed to the next step.
If the answer is no, proceed to Chevrolet Optra Brake Modulator Replacement or
Chevrolet Aveo, Pontiac G3 and Pontiac Wave Brake Modulator Replacement in this
bulletin.
Page 6
November 2012
Bulletin No.: 12189
11. The ABS Check screen will instruct you to release the brake pedal.
While this screen is displayed, the pump motor is running (1sec).
12. The “Procedure in Progress” message will appear on the ABS Check screen.
When the Tech 2 screen is prompted to “Apply and Hold the Brake Pedal,” the technician should apply
and hold heavy brake force during ABS Check.
Page 7
November 2012
①
Bulletin No.: 12189
②
With the valve open, the pedal will drop for 2 seconds. With the motor pumping, the pedal will push
back for 3 seconds.
13. Apply and hold brake pedal.
14. Answer the question on the ABS Check screen.
If the answer is yes, proceed to the next step.
If the answer is no, proceed to Chevrolet Optra Brake Modulator Replacement or
Chevrolet Aveo, Pontiac G3 and Pontiac Wave Brake Modulator Replacement in this
bulletin.
15. Answer the question on the ABS Check screen.
If the answer is yes, proceed to the next step.
If the answer is no, proceed to Chevrolet Optra Brake Modulator Replacement or
Chevrolet Aveo, Pontiac G3 and Pontiac Wave Brake Modulator Replacement in this
bulletin.
Page 8
November 2012
Bulletin No.: 12189
16. The ABS Check screen will instruct you to release the brake pedal.
While this screen is displayed, the pump motor is running (1sec).
17. The “Procedure in Progress” message will appear on the ABS Check screen.
When the Tech 2 screen is prompted to “Apply and Hold the Brake Pedal,” the technician should apply
and hold heavy brake force during ABS Check.
Page 9
November 2012
①
Bulletin No.: 12189
②
With the valve open, the pedal will drop for 2 seconds. With the motor pumping, the pedal will push
back for 3 seconds.
18. Apply and hold brake pedal.
19. Answer the question on the ABS Check screen.
If the answer is yes, proceed to the next step.
If the answer is no, proceed to Chevrolet Optra Brake Modulator Replacement or
Chevrolet Aveo, Pontiac G3 and Pontiac Wave Brake Modulator Replacement in this
bulletin.
20. Answer the question on the ABS Check screen.
If the answer is yes, proceed to the next step.
If the answer is no, proceed to Chevrolet Optra Brake Modulator Replacement or
Chevrolet Aveo, Pontiac G3 and Pontiac Wave Brake Modulator Replacement in this
bulletin.
Page 10
November 2012
Bulletin No.: 12189
21. The ABS Check screen will instruct you to release the brake pedal.
While this screen is displayed, the pump motor is running (1sec).
22. The “Procedure in Progress” message will appear on the ABS Check screen.
When the Tech 2 screen is prompted to “Apply and Hold the Brake Pedal,” the technician should apply
and hold heavy brake force during ABS Check.
Page 11
①
November 2012
Bulletin No.: 12189
②
With the valve open, the pedal will drop for 2 seconds. With the motor pumping, the pedal will push
back for 3 seconds.
23. Apply and hold brake pedal.
24. Answer the question on the ABS Check screen.
If the answer is yes, proceed to the next step.
If the answer is no, proceed to Chevrolet Optra Brake Modulator Replacement or
Chevrolet Aveo, Pontiac G3 and Pontiac Wave Brake Modulator Replacement in this
bulletin.
25. Answer the question on the ABS Check screen.
If the answer is yes, proceed to the next step.
If the answer is no, proceed to Chevrolet Optra Brake Modulator Replacement or
Chevrolet Aveo, Pontiac G3 and Pontiac Wave Brake Modulator Replacement in this
bulletin.
Page 12
November 2012
Bulletin No.: 12189
26. The ABS Check screen will instruct you to release the brake pedal.
27. The “Procedure Passed “message will appear on the ABS Check screen.
Brake Valve Cycling
Warning: Brake fluid may irritate eyes and skin. In case of contact, take the following actions:
Eye contact—rinse thoroughly with water.
Skin contact—wash with soap and water.
If ingested—consult a physician immediately.
Warning: During the Brake Valve Cycling procedure, battery shortage may occur. It is
recommended you connect secondary power supply to battery for battery shortage prevention.
1.
Connect required brake bleeding equipment.
2.
Raise and support vehicle. Refer to Lifting and Jacking the Vehicle in SI.
3.
Remove all tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in
SI.
4.
Drain brake fluid from the brake system.
Note: Fill the master cylinder reservoir with brake fluid. Keep the master cylinder at least 1/2 full
of fluid during the brake bleeding operation. Fill brake system with Delco Supreme 11 Brake
Fluid (P/N 19299818 USA, P/N 19299819 Canada).
5.
Bleed the brake system. (DO NOT perform air bleeding through scan tool). Refer to
Hydraulic Brake System Bleeding in SI.
Page 13
6.
November 2012
Bulletin No.: 12189
Connect scan tool.
2911424
7.
Select “F2.Special Functions” and then Select “F2.Brake Valve Cycling”.
8.
Start brake valve cycling.
This screen displays when the Tech 2 is starting to communicate with the vehicle.
9.
Waiting for data.
Page 14
November 2012
Bulletin No.: 12189
10. The “Procedure in Progress” message will appear from the Brake Valve Cycling screen.
11. The “Apply and Hold Brake Pedal” message will appear from the Brake Valve Cycling
screen.
Page 15
November 2012
Bulletin No.: 12189
The auto brake valve cycling process will run for 25 seconds. A little pedal down/up will occur during
the process.
12. The “Procedure in Progress” message will appear from the Brake Valve Cycling screen.
Note: Perform base brake bleed for ONLY the front wheel circuits after each loop has been
completed. Open each front caliper bleeder valve 1 time for 1-2 seconds and then close it. This
will only extract a very small quantity of brake fluid from each front caliper. Then proceed to the
next loop or count. Repeat steps 11 -13 until the 10th loop has been counted. The procedure is
automatic; the procedure will only complete 10 loops and then stop.
13. The “Release Brake Pedal” message will appear from the Brake Valve Cycling screen.
Page 16
November 2012
Bulletin No.: 12189
14. The “Procedure Complete” message will appear on the Brake Valve Cycling screen.
15. To ensure the brake system is functioning properly, perform the ABS Module Inspection
procedure again. Refer to ABS Module Inspection in this bulletin.
Chevrolet Optra Brake Pressure Modulator Replacement
Warning: Brake fluid may irritate eyes and skin. In case of contact, take the following actions:
Eye contact—rinse thoroughly with water.
Skin contact—wash with soap and water.
If ingested—consult a physician immediately.
Removal Procedure
1.
Drain the brake fluid from the brake system.
2.
Turn the ignition switch to the OFF position.
3.
Drain the engine coolant to below the level of the surge tank.
4.
Loosen the return hose clamp and disconnect the return hose from the top of the surge
tank.
5.
Loosen the throttle body hose clamp and disconnect the throttle body hose from the top of
the surge tank.
Page 17
November 2012
Bulletin No.: 12189
1291103
6.
Loosen the feed hose clamp and disconnect the feed hose from the bottom of the surge
tank.
7.
Remove the surge tank attaching bolt.
1291113
8.
- Mixes well with conventional fluids
- Low-moisture formula provides excellent vapor lock...
- Ideal for hydraulic and disc brakes
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TSB/Document ID: 12189
Replacement Service Bulletin Number:
MFR Communication Date: 2012-11-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: UNKNOWN OR OTHER
MFR Component System:
MFR Component Subsystem:
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