Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 174
INSTALL
(1) Install pump/motor assembly in reverse order of
removal.
(2) Tighten the pump/motor assembly fluid lines to
the torque values shown below.
• Low pressure hose clamp. 1 NIm (10 in. lbs.)
• High pressure hose fitting to pump/motor assembly.
16 N
Im (145 in. lbs.) Fig. 5.
CAUTION:Be sure the high pressure hose routing
clip, is securely fastened to the battery tray and hose,
when hose is reinstalled (See Fig. 5).
BRAKE FLUID PRESSURE AND RETURN
HOSES (FIG. 6)
REMOVE
(1) Remove the pump/motor assembly from its
mounting bracket, see Pump/Motor Service.
(2) Cut the 4 tie straps that secure the high and low
pressure hoses and pump/motor assembly wiring har-
ness together Fig. 6.
(3) Remove the banjo bolt and spray shield from the
pump/motor assembly Fig. 6.
(4) Remove the high and low pressure hose assembly
from the pump/motor assembly Fig. 6.
INSTALL
(1) The rubber O-Rings used on the high and low
pressure hose connections to the pump/motor assem-
bly. Should be lubricated with clean brake fluid before
connecting hoses to pump/motor assembly.
(2) Position high and low pressure hoses and spray
shield on the pump/motor assembly (Fig. 6). Then
install the banjo bolt and torque to 14 N
Im (120 in.lbs.)
(3) Carefully route wiring harness along the side of
the high and low pressure hose assembly Fig. 6.
(4) Install the 4 tie straps around the hose assembly
and wiring harness per the sequence and locations
shown in (Fig. 6).
(5) Install the pump/motor assembly back on mount-
ing bracket, See Pump/Motor Service.
(6) Turn the ignition switch to the RUN position.
This will turn on the pump/motor assembly to charge
the high pressure system.
Fig. 5 Brake Tube and Hose Routing
Fig. 6 Positioning Tie Straps
.
ANTI-LOCK BRAKES
5 - 79
(7) Pump the brake system down as detailed in
De-pressurizing Hydraulic Accumulator in this section
of the service manual.
(8) Fill the hydraulic assembly to the proper level
with Mopar
t brake fluid or an equivalent meeting DOT
3 specifications. See Master Cylinder Fluid Level in the
Service Adjustments section of this group.
HYDRAULIC ASSEMBLY
REMOVE
(1) De-pressurize the hydraulic accumulator by
pumping the brake pedal a minimum of 40 times.
Using the procedure as described in De-Pressurizing
Hydraulic Accumulator listed earlier in this section.
WARNING: FAILURE TO DE-PRESSURIZE HYDRAU-
LIC ACCUMULATOR, BEFORE PERFORMING THIS
OPERATION, MAY RESULT IN PERSONAL INJURY
AND/OR DAMAGE TO PAINTED SURFACES.
(2) Remove fresh air intake duct and air cleaner
from vehicle.
(3) Remove the windshield washer fluid bottle from
the vehicle.
(4) Disconnect all electrical connectors from the hy-
draulic assembly.
(5) Remove as much fluid as possible from the res-
ervoir on the hydraulic assembly.
(6) Remove pump high pressure hose fitting (Fig. 7)
from hydraulic assembly.
(7) Disconnect pump return hose from steel tube.
Cap the end of the steel tube.
(8) Disconnect the 4 brake tubes from the hydraulic
assembly (Fig. 7).
(9) From under the instrument panel, position a
small screwdriver between the center tang on the
retainer clip and the pin in the brake pedal. Rotate the
screwdriver enough to allow the retainer clip center
tang to pass over the end of the brake pedal pin.
Discard the old retainer clip, a new clip must be
used when hydraulic assembly is reinstalled
(Fig. 8).
(9) Remove the 4 hydraulic assembly to dash panel
mounting nuts from the hydraulic assembly mounting
studs, located under instrument panel (Fig. 8).
(10) Remove hydraulic assembly from vehicle.
INSTALL
(1) Position the hydraulic assembly into its mount-
ing holes on the dash panel of the vehicle.
(2) Install and tighten the 4 hydraulic assembly to
dash panel mounting stud nuts (Fig. 8) to 28 N
Im (250
in. lbs.) torque.
(3) Using lubriplate or equivalent, coat the bearing
surface of the brake pedal pin.
(4) Connect push rod to pedal pin and install a NEW
retainer clip. HYDRAULIC ASSEMBLY PUSH ROD
MUST BE ASSEMBLED TO BRAKE PEDAL PIN
IN THE POSITION AS SHOWN IN (FIG. 8).
(5) Install all 4 brake tubes on the hydraulic assem-
bly (Fig. 7) and torque tube fittings to their specified
values (See Torque Specifications). If proportioning
valves were removed from the hydraulic assembly,
install and tighten to 40 N
Im (30 ft. lbs.) torque.
(6) Install return hose on steel tube. Tighten the
return hose clamp to 1 N
Im (10 in.lbs.)
(7) Install high pressure hose to hydraulic assembly
(Fig. 7). Tighten the hose, to hydraulic assembly fitting
to 16 N
Im (145 in. lbs)
(8) Fill hydraulic assembly brake fluid reservoir to
top of screen on the reservoir filter/strainer (Fig. 9).
(9) Connect all electrical connectors to the hydraulic
assembly.
(10) Bleed the entire brake system, see Bleeding
Brake System in this section of the Service Manual.
(11) Replace all fresh air intake ducts, air cleaner
and washer bottle.
(12) Check that the brake fluid in the hydraulic
assembly is at the correct level before moving vehicle.
(See Checking Brake Fluid Level in this section of the
service manual).
Fig. 7 Brake Tube and Hose Routing at Hydraulic
Unit
5 - 80
ANTI-LOCK BRAKES
.
BRAKE FLUID RESERVOIR
REMOVE
(1) De-pressurize the hydraulic accumulator by
pumping the brake pedal a minimum of 40 times.
Using the procedure as described in De-Pressurizing
Hydraulic Accumulator listed earlier in this section.
WARNING: FAILURE TO DE-PRESSURIZE HYDRAU-
LIC ACCUMULATOR, BEFORE PERFORMING THIS
OPERATION, MAY RESULT IN PERSONAL INJURY
AND/OR DAMAGE TO PAINTED SURFACES.
(2) Remove as much brake fluid as possible from the
fluid reservoir, using a syringe or equivalent method.
(3) Using Oil Filter Band Wrench, Special Tool
C-4065 or equivalent loosen bladder accumulator. Then
remove the bladder accumulator and brake fluid spray
shield from the hydraulic assembly (Fig. 10). Remove
high pressure banjo fitting from hydraulic assembly.
(4) Using needle nose pliers, remove the three fluid
reservoir retaining pins from the hydraulic assembly
(Fig. 11). Compress the barb on the opposite side of
retaining pin to prevent pin from breaking.
(5) Remove reservoir from hydraulic assembly by
CAREFULLY prying between reservoir and hydraulic
assembly with a blunt prying tool (Fig. 12). Use a
rocking motion to help disengage reservoir from grom-
mets while prying. BE EXTREMELY CAREFUL TO
AVOID DAMAGING OR PUNCTURING RESER-
VOIR DURING THIS PROCEDURE.
Fig. 8 Removing or Installing Hydraulic Assembly
Fig. 9 ABS Fill Level On Filter/Strainer
.
ANTI-LOCK BRAKES
5 - 81
(6) Remove the brake fluid level sensor switch from
the reservoir.
Remove switch by compressing the retaining barbs
(Fig. 13) on the end of the switch and then slide switch
out of the brake fluid reservoir (Fig. 14)
(7) Using fingers, remove the 3 reservoir grommets
(Fig. 14) from the hydraulic assembly or reservoir, and
discard. Grommets must not to be reused when
reservoir is installed on hydraulic assembly.
INSTALL
(1) Thoroughly lubricate the new reservoir grom-
mets with clean brake fluid and install on reservoir
outlet ports (Fig. 14). The new reservoir grommets
supplied with reservoir, must ALWAYS be used.
(2) Install brake fluid level switch into brake fluid
reservoir (FIG. 14).
(3) Press reservoir into hydraulic assembly BY
HAND, using a rocking motion to help seat reservoir
into hydraulic assembly. Be sure that grommets are
fully seated in the hydraulic assembly. DO NOT AT-
Fig. 10 Removing Bladder Accumulator
Fig. 11 Remove Reservoir Retaining Pins
Fig. 12 Remove Reservoir From Hydraulic Assembly
Fig. 13 Fluid Switch Retaining Barbs
5 - 82
ANTI-LOCK BRAKES
.
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст