Chrysler RG Voyager. Manual — part 656
(12) Remove vacuum seal located on the mounting
flange of the master cylinder. The vacuum seal is
removed from master cylinder by carefully pulling it
off the rear of master cylinder. Do not attempt to
pry the seal off the master cylinder by inserting
a sharp tool between seal and master cylinder
casting.
REMOVAL - RHD
CAUTION: Vacuum in the power brake booster must
be pumped down (removed) before removing mas-
ter cylinder from power brake booster. This is nec-
essary to prevent the power brake booster from
sucking in any contamination as the master cylin-
der is removed. This can be done simply by pump-
ing the brake pedal, with the vehicle’s engine not
running, until a firm feeling brake pedal is achieved.
(1) With engine not running, pump brake pedal
until a firm pedal is achieved (4 or 5 strokes).
(2) Disconnect negative battery terminal.
(3) Disconnect positive battery terminal.
(4) Remove battery shield.
(5) Remove nut and clamp securing battery to tray,
remove battery.
(6) Thoroughly clean all surfaces of the brake fluid
reservoir and master cylinder. Use only solvent such
as Mopar
t Brake Parts Cleaner or equivalent.
(7) Remove wiring harness connector from brake
fluid level switch in master cylinder brake fluid res-
ervoir (Fig. 46).
(8) Disconnect primary and secondary brake tubes
from master cylinder housing (Fig. 50). Install seal-
ing plugs in the now open brake tube outlet ports.
CAUTION: Before removing the master cylinder
from the power brake vacuum booster, the master
cylinder and vacuum booster must be thoroughly
cleaned. This must be done to prevent dirt particles
from falling into the power brake vacuum booster.
(9) Clean area where master cylinder assembly
attaches to power brake booster. Use only a solvent
such as Mopar
t Brake Parts Cleaner or equivalent.
(10) Remove two nuts attaching master cylinder to
power brake booster (Fig. 50).
(11) Slide master cylinder straight out of power
brake booster.
CAUTION: A seal on the rear of the master cylinder
is used to create the seal for holding vacuum in the
power brake vacuum booster. The vacuum seal on
the master cylinder MUST be replaced whenever the
master cylinder is removed from the power brake
vacuum booster.
(12) Remove vacuum seal located on the mounting
flange of the master cylinder. The vacuum seal is
removed from master cylinder by carefully pulling it
off the rear of master cylinder. Do not attempt to
pry the seal off the master cylinder by inserting
a sharp tool between seal and master cylinder
casting.
DISASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR)
(1) Clean master cylinder housing and brake fluid
reservoir. Use only a solvent such as Mopar Brake
Parts Cleaner or an equivalent.
(2) Remove brake fluid reservoir cap. Using a
syringe or equivalent type tool empty as much brake
fluid as possible from the reservoir.
CAUTION: When removing fluid reservoir from the
master cylinder, do not pry off using any type of
tool. This can damage the fluid reservoir or master
cylinder housing.
(3) Remove the master cylinder assembly from the
power brake vacuum booster. (Refer to 5 - BRAKES -
BASE/HYDRAULIC/MECHANICAL/MASTER
CYL-
INDER - REMOVAL).
(4) Mount the master cylinder in a vise using the
master cylinder mounting flange.
(5) Using correct size pin punch, remove the two
retaining pins between the fluid reservoir and master
cylinder housing (Fig. 51).
(6) Rock the brake fluid reservoir from side to side
while pulling up to remove it from the seal grommets
in master cylinder housing.
(7) Remove the two master cylinder housing to
brake fluid reservoir seal grommets (Fig. 52).
Fig. 50 RHD MASTER CYLINDER MOUNTING
1 - PRIMARY BRAKE TUBE NUT
2 - SECONDARY BRAKE TUBE NUT
3 - MASTER CYLINDER MOUNTING NUTS
RS
BRAKES - BASE
5 - 37
MASTER CYLINDER (Continued)
ASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR)
(1) Install new master cylinder housing to brake
fluid reservoir sealing grommets in master cylinder
housing (Fig. 52).
(2) Lubricate reservoir mounting area with fresh
clean brake fluid. Place reservoir in position over
sealing grommets. Seat reservoir into sealing grom-
mets using a rocking motion while firmly pressing
down on fluid reservoir.
(3) Be sure fluid reservoir is positioned properly on
master cylinder. Bottom of fluid reservoir is to be
touching the top of both sealing grommets
when properly installed on master cylinder
housing.
(4) Install the two fluid reservoir to master cylin-
der retaining pins (Fig. 51).
(5) Install the master cylinder assembly on the
power brake booster. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/MASTER
CYLINDER
-
INSTALLATION)
(6) Fill fluid reservoir to its proper level as indi-
cated on the side of the fluid reservoir.
INSTALLATION
INSTALLATION - LHD
CAUTION: Different types of master cylinders are
used on this vehicle depending on brake options. If
a new master cylinder is being installed, be sure it
is the correct master cylinder for the type of brake
system the vehicle is equipped with.
CAUTION: When replacing the master cylinder on a
vehicle, a NEW vacuum seal MUST be installed on
the master cylinder.
(1) Install a NEW vacuum seal on master cylinder
making sure seal fits squarely in groove of master
cylinder casting.
(2) Position master cylinder on studs of power
brake booster, aligning booster push rod with master
cylinder piston.
(3) Install the two master cylinder mounting nuts
(Fig. 49). Tighten both mounting nuts to a torque of
25 N·m (225 in. lbs.).
CAUTION: When tightening the primary and sec-
ondary brake tube nuts at master cylinder, be sure
brake tubes do not contact any other components
within the vehicle and that there is slack in the flex-
ible sections of the tubes. This is required due to
the movement between the ABS ICU and the master
cylinder while the vehicle is in motion.
(4) Connect primary and secondary brake tubes to
master cylinder primary and secondary ports (Fig.
48). Brake tubes must be held securely when tight-
ened to control orientation of flex section. Tighten
tube nuts to a torque of 17 N·m (145 in. lbs.).
(5) Install wiring harness connector to brake fluid
level switch mounted in brake fluid reservoir (Fig.
48).
(6) Install battery, clamp and nut.
(7) Install battery shield.
(8) Connect positive battery terminal.
(9) Connect negative battery terminal.
(10) Fill master cylinder with clean, fresh Mopar
t
Brake Fluid or equivalent.
Fig. 51 Fluid Reservoir Retaining Pins (Typical)
1 - FLUID RESERVOIR
2 - RETAINING PINS
3 - MASTER CYLINDER
Fig. 52 Master Cylinder To Fluid Reservoir Seal
Grommets
1 - SEAL GROMMETS
2 - MASTER CYLINDER
5 - 38
BRAKES - BASE
RS
MASTER CYLINDER (Continued)
(11) Road test vehicle to ensure proper operation of
brakes.
INSTALLATION - RHD
CAUTION: Different types of master cylinders are
used on this vehicle depending on brake options. If
a new master cylinder is being installed, be sure it
is the correct master cylinder for the type of brake
system the vehicle is equipped with.
CAUTION: When replacing the master cylinder on a
vehicle, a NEW vacuum seal MUST be installed on
the master cylinder.
(1) Install a NEW vacuum seal on master cylinder
making sure seal fits squarely in groove of master
cylinder casting.
(2) Position master cylinder on studs of power
brake booster, aligning booster push rod with master
cylinder piston.
(3) Install the two master cylinder mounting nuts
(Fig. 50). Tighten both mounting nuts to a torque of
25 N·m (225 in. lbs.).
CAUTION: When tightening the primary and sec-
ondary brake tube nuts at master cylinder, be sure
brake tubes do not contact any other components
within the vehicle and that there is slack in the flex-
ible sections of the tubes. This is required due to
the movement between the ABS ICU and the master
cylinder while the vehicle is in motion.
(4) Connect primary and secondary brake tubes to
master cylinder primary and secondary ports (Fig.
50). Brake tubes must be held securely when tight-
ened to control orientation of flex section. Tighten
tube nuts to a torque of 17 N·m (145 in. lbs.).
(5) Install wiring harness connector to brake fluid
level switch mounted in brake fluid reservoir (Fig.
46).
(6) Install battery, clamp and nut.
(7) Install battery shield.
(8) Connect positive battery terminal.
(9) Connect negative battery terminal.
(10) Fill master cylinder with clean, fresh Mopar
t
Brake Fluid or equivalent.
(11) Road test vehicle to ensure proper operation of
brakes.
PEDALS - ADJUSTABLE
REMOVAL
NOTE: Before proceeding, review all Steering Col-
umn and Airbag Warnings and Cautions. (Refer to
19 - STEERING/COLUMN - WARNING) (Refer to 8 -
ELECTRICAL/RESTRAINTS - WARNING)
(1) Move driver’s seat to full rearward position.
(2) Disconnect negative battery cable from battery
post and isolate.
(3) Remove throttle cable from throttle body lever.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE CONTROL CABLE - REMOVAL)
(4) Remove screws securing lower steering column
cover/knee blocker, then remove it (Fig. 53).
(5) Disconnect
parking
brake
release
link
at
release handle.
(6) Compress tabs on sides of data link diagnostic
connector and remove it from knee blocker reinforce-
ment plate.
(7) Remove screws securing knee blocker reinforce-
ment plate in place, then remove reinforcement plate
(Fig. 53).
(8) Remove hood release from lower left reinforce-
ment.
(9) Remove
screws
securing
instrument
panel
lower left reinforcement in place, then remove rein-
forcement (Fig. 54).
Fig. 53 Lower Steering Column Cover And
Reinforcement
1 - INSTRUMENT PANEL
2 - REINFORCEMENT PLATE
3 - LOWER STEERING COLUMN COVER/KNEE BLOCKER
RS
BRAKES - BASE
5 - 39
MASTER CYLINDER (Continued)
(10) Remove brake lamp switch. Discard original
switch; it must not be reused. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING
-
EXTERIOR/BRAKE
LAMP SWITCH - REMOVAL)
(11) Remove upper and lower steering column
shrouds.
(Refer
to
19
-
STEERING/COLUMN/
LOWER SHROUD - REMOVAL)
(12) Disconnect
wiring
harness
connectors
(as
equipped) from clockspring, multi-function switch,
SKIM module, ignition switch and BTSI solenoid.
(13) If equipped, disconnect PRNDL cable from
shift lever and column bracket (Fig. 55).
(14) Disconnect shift cable at shift lever mecha-
nism pin (Fig. 55).
(15) Remove pinch side clip, then remove shift
cable from bracket on column.
(16) Place front wheels in STRAIGHT-AHEAD
position, then secure steering wheel to column in this
position using appropriate retaining method.
(17) Remove pinch bolt securing column coupling
to intermediate shaft (Fig. 56).
(18) Loosen two lower steering column mounting
nuts.
(19) Remove two upper steering column mounting
nuts.
(20) Remove steering column assembly.
(21) Remove dash seal silencer shell over steering
column intermediate shaft (Fig. 57).
Fig. 54 Instrument Panel Lower Left Reinforcement
1 - INSTRUMENT PANEL LOWER REINFORCEMENT
2 - STEERING WHEEL
3 - LOWER LEFT REINFORCEMENT
Fig. 55 Shift Cable At Steering Column
1 - SHIFT LEVER MECHANISM
2 - SHIFT CABLE
3 - BRACKET
4 - PRNDL CABLE (IF EQUIPPED)
5 - STEERING COLUMN
Fig. 56 Pinch Bolt
1 - PINCH BOLT
2 - STEERING COLUMN
5 - 40
BRAKES - BASE
RS
PEDALS - ADJUSTABLE (Continued)
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст