Remove the surge tank from the support mount.

Warning: Wear safety glasses in order to avoid eye damage.
9. Clean the brake modulator assembly pipe fitting areas of any accumulated dirt and foreign
material.

2911426

10. Disconnect the electrical connector from the electronic brake control module (EBCM).
11. Place a shop towel under the brake modulator assembly to catch any brake fluid loss.

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Note: Prior to disconnecting the brake pipes from the antilock brake system (ABS) modulator
assembly, note the locations of the brake pipes to the valve assembly, to aid during installation.

2911429

12. Disconnect the brake pipe fitting nuts from the brake pressure modulator valve (BPMV).
13. Cap the brake pipe ends to prevent brake fluid loss and contamination.
14. Plug the modulator brake pipe openings to prevent brake fluid loss and contamination.
15. Remove the mounting bracket bolt and nuts from the body panel.

2911431

16. Remove the brake modulator assembly to the mounting bracket damping bolts.

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November 2012

2911413

17. Remove the ABS module from bracket.

2911416

18. Remove the mounting pins from ABS module.

Bulletin No.: 12189

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2911420

19. Remove the HCU from EBCM. (ABS: 3 bolts, ESC: 4 bolts).
20. Install new HCU onto EBCM. Tighten the mounting bolts to 1.8 Nm (16 lb-in).
21. Install the mounting pins from ABS module. Tighten mounting pins: 8 Nm (6 lb–ft).
22. Install the brake modulator assembly to the modulator bracket. Tighten mounting bolts: 8
Nm (6 lb–ft).
23. Install the damping bolts to the brake modulator assembly. Tighten the damping bolts to the
brake modulator assembly to 11 N.m (8 lb–ft).
24. Install the brake modulator assembly with the mounting bracket attached to the body panel.
Tighten the mounting bracket bolt and nuts to 22 Nm (16 lb-ft).
25. Remove the caps from the master cylinder brake pipe ends.
26. Remove the plugs from the master cylinder ports on the modulator assembly.
27. Connect the master cylinder brake pipes to the modulator assembly, in the same location as
removed.
28. Tighten the brake pipe fittings nuts. Tighten the fitting nuts to 16 Nm (12 lb–ft).
29. Connect the electrical connector to the EBCM.
Note: Refill coolant in the reservior tank properly. It may need about one liter.
30. Install the engine coolant reservior tank.
Note: Fill the master cylinder reservoir with brake fluid. Ensure the master cylinder is 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).
31. Bleed the brake system. Refer to Hydraulic Brake System Bleeding in SI.

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Bulletin No.: 12189

Chevrolet Aveo, Pontiac G3 and Pontiac Wave 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.

1.

Drain the brake fluid from the brake system.

1241628

Warning: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK
position, and all electrical loads must be OFF before servicing any electrical component.
Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment
come in contact with an exposed electrical terminal. Failure to follow these precautions may
result in personal injury and/or damage to the vehicle or its components. For Vehicles equipped
with OnStar® (UE1) with Back Up Battery: The Back Up Battery is a redundant power supply to
allow limited OnStar® functionality in the event of a main vehicle battery power disruption to the
VCIM (OnStar® module). Do not disconnect the main vehicle battery or remove the OnStar®
fuse with the ignition key in any position other than OFF. Retained accessory power (RAP)
should be allowed to time out or be disabled (simply opening the driver door should disable
RAP) before disconnecting power. Disconnecting power to the OnStar® module in any way
while the ignition is On or with RAP activated may cause activation of the OnStar® Back-Up
Battery (BUB) system and will discharge and permanently damage the back-up battery. Once
the Back-Up Battery is activated it will stay on until it has completely discharged. The BUB is not
rechargeable and once activated the BUB must be replaced.
2.

Disconnect the negative battery cable and then disconnect the positive battery cable.

3.

Remove the nuts from the battery rods that fasten the battery hold-down bar clamp.

4.

Remove the battery from the vehicle.

5.

Unlock the retaining tabs on the fuse block and remove the cover.

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2786707

Note: Do not separate the fuse block from the housing. Do not remove the wiring harness from
the fuse block.
6.

Remove the fuse block positive battery cable nut (1) and the positive battery cable (2).

2786728.

Note: Illustration shows fuse block out of housing for illustration purposes only. Remove the fuse
block and housing as one assembly.
7.

Remove fuse block housing bolt (1) and fuse block housing (2) from current location with
fuse block and housing as one assembly.

Caution: The fuse block wiring harness will limit where you can place the fuse block. Do not
attempt to move the fuse block further than what the wiring harness will permit.
8.

Move fuse block and fuse block housing away from work area in the engine compartment.

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November 2012

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1245647

9.

Disconnect the electrical connector from the master cylinder reservoir.

1241824

Note: Do not remove the radiator surge tank coolant feed hose. Plug surge tank overflow outlet
on the tank, if required.
10. Disconnect the radiator surge tank overflow hose located next to the radiator surge tank
attachment fasteners.

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1241826

11. Remove radiator surge tank attachment nuts.
Caution: The radiator surge tank coolant feed hose will limit where you place the radiator surge
tank. Do not attempt to move the radiator surge tank further than the coolant feed hose will
permit.
12. Move radiator surge tank away from work area in the engine compartment.

1779013

13. Disconnect the electronic brake control module (EBCM) wiring harness connector.
14. Cover the connector and the socket with shop cloths to protect them from brake fluid.

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November 2012

Bulletin No.: 12189

Note: Take care not to allow air into the hydraulic unit or into the brake pipes from the master
cylinder. If air gets into the hydraulic unit, it will require a bleeding procedure using a scan tool
programmed for the ABS 5.3 system. As long as no air enters the hydraulic unit, a simple
bleeding procedure is all the system will require.

1779018

15. Remove the brake pipes from the brake pressure modulator valve (BMPV) assembly.
16. Plug the brake pipes.
17. Remove the mounting bracket bolts on the BMPV assembly.
18. Remove the ABS module bracket assembly from vehicle.

2911413

19. Remove the ABS module from bracket.

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2911429

20. Remove the mounting pins (1) from ABS module.

2911431

21. Remove the fastners (2) seuring the HCU to the EBCM.
22. Install new HCU on the EBCM. Tighten mounting bolts to 1.8 Nm (16 lb-ft).
23. Install ABS module mounting pins. Tighten mounting pins: 8 Nm (6 lb–ft).
24. Install the brake modulator assembly to the modulator bracket.
Tighten mounting bolts: 8 Nm (6 lb–ft).
25. Install the BPMV assembly into the mounting bracket. Secure with two nuts and tighten to
16 Nm (12 lb-ft).

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1779018

26. Remove the plugs from the brake pipes and connect the brake pipes to the BPMV
assembly and tighten to 22 Nm (16 lb-ft).

1779013

27. Connect the wiring harness EBCM connector.
28. Place fuse block assembly back into its original location.

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2786728

Note: Illustration shows fuse block out of housing for illustration purposes only. Install the fuse
block and housing as one assembly.
29. Install the fuse block housing bolts (1) and tighten to 7 N·m (62 lb in).

2786707

30. Install the fuse block positive battery cable nut (1) and the positive battery cable (2) and
tighten to 10 N·m (89 lb in).
31. Install fuse block cover.

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November 2012

1245647

32. Connect the master cylinder electrical connector.
33. Place the radiator surge tank into its original location.

1241826

34. Install the radiator surge tanks attachment nuts.

Bulletin No.: 12189

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1241824

35. Connect the radiator surge tank overflow hose.

1241628

36. Install the battery into the tray.
37. Fasten the bar clamp to the battery by loosely attaching the battery rods from the battery
tray cutouts through the bar clamp holes, and loosely tightening the nuts.
38. Tighten the battery retainer clamp-to-battery rod nuts to 4 N·m (35 lb in).
39. Connect the negative and positive battery cables.
40. Tighten the battery cable nuts to 4.5 N·m (40 lb in).
Note: Fill the master cylinder reservoir with brake fluid. Ensure the master cylinder is 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).
41. Bleed the brake system. Refer to Hydraulic Brake System Bleeding in SI.
42. Place a copy of the Owner Manual Supplement (found on the next page) in the customer's
owner manual.

Owner Manual Supplement
Please place this in the “Recommended Fluids and Lubricants” section of your Owner Manual

Below are the GM recommended brake fluids. Using brake fluid other than GM recommended
brake fluid may cause corrosion to components of the brake system. Corrosion may make the
brake system not work well and could cause a crash.
Usage
Hydraulic Brake
System

Fluid/Lubricant
Delco Supreme 11 Brake Fluid
(GM Part No. U.S. 19299818, in Canada 19299819)

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November 2012

Bulletin No.: 12189

CUSTOMER REIMBURSEMENT - For US
Customer requests for reimbursement of previously paid repairs for the recall condition are to be
submitted to the dealer by November 30, 2013, unless otherwise specified by state law. If this is
not convenient for the customer, they may mail the completed Customer Reimbursement
Request Form and all required documents to the GM Customer Assistance Center.
All reasonable and customary costs to correct the condition described in this bulletin
should be considered for reimbursement. Any questions or concerns should be
reviewed with your GM Representative prior to processing the request.
When a customer requests reimbursement, they must provide the following:




A completed Customer Reimbursement Request Form. This form is mailed to the
customer or can be obtained through GM GlobalConnect.
The name and address of the person who paid for the repair.
Paid receipt confirming the amount of the repair expense, a description of the repair, and
the person or entity performing the repair.

IMPORTANT: GM requires dealers to approve or deny a reimbursement request within 30 days
of receipt. If a reimbursement request is approved, the dealer should immediately issue a check
to the customer and submit an appropriate warranty transaction for the incurred expense. If a
reimbursement request is denied, the dealer MUST provide the customer with a clear and
concise explanation, in writing, as to why the request was denied. The bottom portion of the
Customer Reimbursement Request Form may be used for this purpose. If the denial was due to
missing documents, the customer can resubmit the request when the missing documents are
obtained, as long as it is still within the allowed reimbursement period.
Warranty transactions for customer reimbursement of previously paid repairs are to be
submitted as required by GM Global Warranty Management. Additional information can also be
found in Warranty Administration Bulletin 11-00-89-004.
CUSTOMER REIMBURSEMENT - For Canada
Customer requests for reimbursement of previously paid repairs to correct the condition
described in this bulletin are to be submitted to the dealer prior to or by November 30, 2013.
When a customer requests reimbursement, they must provide the following:
-

Proof of ownership at time of repair.
Original paid receipt confirming the amount of unreimbursed repair expense(s) (including
Service Contract deductibles), a description of the repair, and the person or entity
performing the repair.

All reasonable and customary costs to correct the condition described in this bulletin should be
considered for reimbursement. Any questions or concerns should be reviewed with your GM
representative prior to processing the request.

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November 2012

Bulletin No.: 12189

WARRANTY TRANSACTION INFORMATION
Submit a transaction using the table below.
Labor
Code
V2636
V2637

Description
Inspect ABS Module (no replacement necessary) (inc brake fluid change)
Inspect & Replace ABS Module (inc brake fluid change)
- Optra
- Aveo, G3, Wave
V2667* Customer Reimbursement Approved
V2668 Customer Reimbursement Denied - For US dealers only

Labor
Time
2.3
1.5
2.0
0.2
0.1

* Customer reimbursement will not close this program. The service procedure must also be
performed on the vehicle.
CUSTOMER NOTIFICATION
General Motors will notify customers of this program on their vehicle (see copy of customer letter
included with this bulletin).
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the attached sample letter.
DEALER PROGRAM RESPONSIBILITY
All unsold new vehicles in dealers' possession and subject to this program must be held and
inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this program at no charge to customers, regardless
of mileage, age of vehicle, or ownership, through November 30, 2014.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for
which there is no customer information indicated on the involved vehicle listing, are to be
contacted by the dealer. Arrangements are to be made to make the required correction
according to the instructions contained in this bulletin. A copy of the customer letter is provided
in this bulletin for your use in contacting customers. Program follow-up cards should not be
used for this purpose, since the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in
your facility for service through November 30, 2014, you must take the steps necessary to be
sure the program correction has been made before selling or releasing the vehicle.

GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions
that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the
tools, equipment, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin
applies to your vehicle, or that your vehicle will have that condition. See your dealer for information on whether your vehicle may benefit from the
information.

We Support
Voluntary Technician
Certification

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November 2012

Bulletin No.: 12189
November 2012

Dear General Motors Customer:
We have learned that your 2007 model year Chevrolet Optra, 2009 model year Pontiac G3 or
Wave, or 2009-2010 model year Chevrolet Aveo may contain brake fluid that does not inhibit
corrosion in the zinc plating on the anti-lock 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.
Your satisfaction with your GM vehicle is very important to us, so we are announcing a program
to prevent this condition or, if it has occurred, to fix it.
What We Will Do: Your GM dealer will inspect the ABS module and, if necessary, replace the
module. Your dealer will also change the brake fluid and provide you with a supplement to the
Owner Manual that lists the GM recommended brake fluid. This service will be performed for
you at no charge until November 30, 2014.
What You Should Do: To limit any possible inconvenience, we recommend that you contact
your dealer as soon as possible to schedule an appointment for this repair. If the inspection
indicates that the ABS module requires replacement, your dealer may need your vehicle for a
day or two while they obtain a new module.
Reimbursement: If you have paid for repairs for the condition described in this letter, please
complete the enclosed form and present it to your dealer with all required documents. Working
with your dealer will expedite your request, however, if this is not convenient, you may mail the
completed form and all required documents to Reimbursement Department, PO Box 33170,
Detroit, MI 48232-5170. The completed form and required documents must be presented to
your dealer or received by the Reimbursement Department by November 30, 2013, unless state
law specifies a longer reimbursement period. Even though you may have already had this
condition corrected, you will still need to take your vehicle to your dealer for additional repairs.
If you have any questions or concerns that your dealer is unable to resolve, please contact the
appropriate Customer Assistance Center at the number listed below.
Division

Number

Chevrolet
Pontiac
Guam
Puerto Rico – English
Puerto Rico – Español
Virgin Islands

1-800-222-1020
1-800-762-2737
65-6267-1752
1-800-496-9992
1-800-496-9993
1-800-496-9994

Text Telephones
(TTY)
1-800-833-2438
1-800-833-7668

Page 35

November 2012

Bulletin No.: 12189

We sincerely regret any inconvenience or concern that this situation may cause you. We want
you to know that we will do our best, throughout your ownership experience, to ensure that your
GM vehicle provides you many miles of enjoyable driving.

Jim Moloney
General Director,
Customer and Relationship Services
Enclosure
12189