1993 CHEVROLET DYNASTY abs

Brake Warning Lamp may indicate reduced
braking ability. The following procedure should
be used to test drive an ABS complaint:(1) Ignition on. Turn the ignition to the ON position
without starting the car and wait until the Red Brake
Warning Lamp and Amber Anti-Lock Warning Lamp
turn off. This will allow the pump to charge the
accumulator to operating pressure. If the warning
lamp(s) do not turn off, go to step 3. (2) Ignition off for 15 seconds.
(3) Start car. Wait for displays to return to normal
operating mode before proceeding. (4) With Shift lever in PARK, slowly depress brake
pedal and release. (5) Drive vehicle a short distance. During this test
drive, be sure that the vehicle achieves at least 20 mph.
Then brake to at least one complete stop and accelerate
slowly back up to at least 20 mph. (6) If a functional problem with the A.B.S. system is
determined while test driving a vehicle. Refer to the
Bendix Anti-Lock 10 Diagnostics Manual for required
test procedures and proper use of the DRB II tester.
CAUTION: The following are general precautions that
should be observed when servicing and diagnosing
the ABS system and/or other vehicle systems. Failure
to observe these precautions may result in ABS
system damage.
(1) If welding work is to be performed on the vehicle
using an arc welder, the (CAB) should be disconnected
before the welding operation begins. (2) The (CAB) and hydraulic assembly 10 way con-
nectors should never be connected or disconnected with
the ignition on. (3) Some components of the ABS system are not
serviced separately and must be serviced as complete
assemblies. Do not disassemble any component which
is designated as non-serviceable. (4) Always de-pressurize the Hydraulic Accu-
mulator when performing any work that re-
quires disconnecting any hydraulic tube, flex
hose or fitting. The ABS system uses brake fluid
at high pressure. Failure to de-pressurize the
accumulator may result in personal injury
and/or damage to painted surfaces. Brake fluid will damage painted surfaces. If brake
fluid is spilled on any painted surfaces, wash off with
water immediately.
DE-PRESSURIZING HYDRAULIC ACCUMULA- TOR
The ABS pump/motor assembly keeps the hydraulic
accumulator charged between approximately 11,032
and 13,790 kPa (1600 and 2000 psi) anytime key is in the ON position. The pump/motor assembly
cannot run if the ignition is off or either battery ca-
ble is disconnected. Unless otherwise specified, the hydraulic accumu-
lator should be de-pressurized before disassembling
any portion of the hydraulic system. The following
procedure should be used to de-pressurize the hy-
draulic accumulator: (1) With ignition off, or either battery cable discon-
nected, pump the brake pedal a minimum of 40 times
using approximately 50 pounds of pedal force. A no-
ticeable change in pedal feel will occur when the ac-
cumulator becomes discharged. (2) When a definite increase in pedal effort is felt,
pump the pedal a few additional times. This will in-
sure removal of all hydraulic pressure from the
brake system.
WHEEL SPEED SENSOR CABLES
Proper installation of wheel speed sensor cables is
critical to continued ABS system operation. Be sure
that cables are installed and routed properly. Failure
to install cables in their retainers, as shown in Sec-
tion 3 of this manual. May result in contact with
moving parts or over extension of cables, resulting in
an open circuit.
MECHANICAL DIAGNOSTICS AND SERVICE
PROCEDURES
SPECIAL SERVICE TOOLS
Some diagnostic procedures in this section require
the use of special service tools. Each of these tools is
described below.
DRB II DIAGNOSTIC TESTER
Some of the diagnostic procedures that are ex-
plained in this section require the use of the DRB II
DIAGNOSTICS TESTER to insure that proper diag-
nostics are performed. Refer to those sections for
proper testing procedures and the DRB II manual for
its proper operational information.
MST-6163 PRESSURE TESTER
Some diagnostic procedures in this manual require
the use of the MST-6163 pressure gauge and adaptor
(Fig. 2). Pressure Gauge, Special Tool MST-6163 is
required to measure accumulator pressure during
certain phases of ABS operation. The pressure gauge
and adaptor should be installed as follows: (1) De-pressurize the accumulator by pumping the
brake pedal a minimum of 40 times with the ignition
off. The procedure is fully explained under De-Pres-
surizing Hydraulic Accumulator which is described
earlier in this System Diagnosis Section.
Ä ANTI-LOCK 10 BRAKE SYSTEM 5 - 89

WARNING: FAILURE TO DE-PRESSURIZE THE AC-
CUMULATOR PRIOR TO PERFORMING THIS OPER-
ATION MAY RESULT IN PERSONAL INJURY
AND/OR DAMAGE TO PAINTED SURFACES. (2) Remove hydraulic assembly accumulator port
plug,located on right hand side of hydraulic assembly
(Fig. 1).
(3) Install pressure gauge to hydraulic assembly
adaptor into accumulator port of hydraulic assembly
(Fig. 2). Then torque adaptor to 10 N Im (7.5 ft. lbs.).
(4) Install adaptor onto the pressure gauge hose
(Fig. 2) and tighten the fitting to 15 N Im (11 ft. lbs.)
torque. (5) Install pressure gauge and hose adaptor assem-
bly onto the adaptor installed in the hydraulic as-
sembly accumulator port. Then install the retaining
clip into the grove on the accumulator port adaptor
(Fig. 2). MAKE SURE THAT THE RETAINING
CLIP IS INSTALLED ON THE ACCUMULATOR
PORT ADAPTOR BEFORE RE-PRESSURIZING
THE HYDRAULIC SYSTEM.
WARNING: BEFORE REMOVING PRESSURE
GAUGE AND ADAPTOR, BE SURE TO DE-PRES-
SURIZE THE HYDRAULIC ASSEMBLY. THEN IN-
STALL AND TIGHTEN ACCUMULATOR PORT PLUG
TO 12 N IM (9 FT. LBS.).
It is not necessary to bleed the hydraulic assembly
or brake system after installation and removal of the
pressure gauge. Unless additional tubes, hoses, or fit-
tings were removed or loosened.
HYDRAULIC ASSEMBLY INTERNAL LEAK
CHECK
If an internal leak is suspected in the ABS hydrau-
lic circuit, Test Gauge, Special Tool 6685 has been
developed to assist in the diagnostics. This fixture
will assist in determining if there is an internal leak;
and if the leak is in the hydraulic unit or the pump
motor assembly. It can be used whether the pump
shuts off or not. Test Gauge, Special Tool 6685 installation and op-
eration procedure is detailed below. Refer to the Hy-
draulic Pressure Performance Test in the 1993
Bendix Anti-Lock 10 Diagnostic Manual for the re-
quired test procedures.
WARNING: FAILURE TO DE-PRESSURIZE THE AC-
CUMULATOR PRIOR TO PERFORMING THIS OPER-
ATION MAY RESULT IN PERSONAL INJURY
AND/OR DAMAGE TO PAINTED SURFACES.
(1) De-pressurize the accumulator by pumping the
brake pedal a minimum of 40 times with the ignition
off. The procedure is fully explained under De-Pres-
surizing Hydraulic Accumulator which is described
earlier in this System Diagnosis Section. (2) Remove wiring harness connector from dual
function pressure switch on bottom of hydraulic as-
sembly. Connect wiring harness from Test Gauge,
Special Tool 6685 into wiring harness connector re-
moved from dual function pressure switch.Fig. 1 Hydraulic Assembly Accumulator Port Plug Location
Fig. 2 Pressure Gauge and Adapter Installed onHydraulic Assembly
5 - 90 ANTI-LOCK 10 BRAKE SYSTEM Ä

(11) Remove all special tools previously installed,
from the ABS hydraulic assembly. (12) Install accumulator port plug into hydraulic
assembly. Torque accumulator port plug to 12 N Im(9
ft. lbs.). (13) Install high pressure brake hose from the
pump motor assembly into hydraulic fitting on ABS
hydraulic assembly. Torque high pressure brake hose
tube nut to 16 N Im (145 in. lbs.).
(14) Turn ignition switch to the run position to en-
ergize the pump/motor assembly and pressurize hy-
draulic system. Check for leakage at the hydraulic
assembly to hydraulic bladder accumulator fitting. (15) Again de-pressurize accumulator by pumping
brake pedal a minimum of 40 times. Use procedure
described in De-Pressurizing Hydraulic Accumulator
in this section of the service manual. (16) Then check the brake fluid level in the hy-
draulic assembly reservoir. If brake fluid level is low,
fill reservoir to proper level with Mopar tbrake fluid
or equivalent conforming to DOT 3 requirements.
INTERMITTENT FAULTS
As with almost any electronic system, intermittent
faults in the ABS system may be difficult to accu-
rately diagnose. Most intermittent faults are caused by faulty elec-
trical connections or wiring. When an intermittent
fault is encountered, check suspect circuits for: (1) Poor mating of electrical connector halves, or
electrical terminals not fully seated in the connector
body. (2) Improperly formed or damaged electrical termi-
nals. All connector terminals in a suspect circuit
should be carefully reformed to increase contact ten-
sion. (3) Poor terminal to wire connection. This requires
removing the terminal from the connector body and
inspecting for proper terminal to wire connection. If a visual check does not find the cause of the
problem, operate the vehicle in an attempt to dupli-
cate the condition and record the Fault Code. Most failures of the ABS system will disable the
Anti-Lock function for the entire ignition cycle even
if the fault clears before ignition key-off. There are
some failure conditions however, which will allow
ABS operation to resume during the ignition cycle in
which a failure occurred. If the failure conditions are
no longer present. The following conditions may result in intermittent
illumination of the Red Brake Warning Lamp and/or
Amber Anti-Lock Warning Lamp. All other failures
will cause the lamp(s) to remain on until the ignition
switch is turned off. Circuits and or components in-
volving these inputs to the (CAB) should be investi-
gated if a complaint of intermittent warning system
operation is encountered. ²
Low system voltage. If low system voltage is de-
tected by the (CAB), the (CAB) will turn on the Am-
ber Anti-Lock Warning Lamp until normal system
voltage is achieved. Once normal voltage is seen at
the (CAB), normal operation resumes.
² Low Brake Fluid. A low brake fluid condition will
cause the Red Brake Warning Lamp to illuminate.
When the fluid sensor again indicates an acceptable
fluid level, the Red Brake Warning Lamp will go out.
This condition may exist during hard cornering or
while the vehicle is on a grade. If the vehicle is in
motion above 3 M.P.H. the Amber Anti-Lock Warn-
ing Lamp will also be turned on.
² Low Accumulator Pressure. Low Accumulator
Pressure will cause both the Red Brake Warning and
Amber Anti-Lock Warning Lamps to illuminate.
Once normal operating pressure is achieved, the
lamps will extinguish and the system will return to
normal operation. Additionally, any condition that results in an inter-
ruption of power to the (CAB) or hydraulic assembly.
May cause the Red Brake Warning and Amber Anti-
Lock Warning Lamps to illuminate intermittently. All the conditions (or faults) mentioned above, can
store a fault code in the (CAB) module.
ABS BRAKE SYSTEM DIAGNOSTIC FEATURES
SYSTEM SELF DIAGNOSIS
The ABS system is equipped with a diagnostic ca-
pability that may be used to assist in isolation of
ABS faults. The features of the diagnostics system
are described below.
CONTROLLER ANTI-LOCK BRAKE (CAB)
Fault codes are kept in a Non-Volatile memory un-
til either erased by the technician using the DRB II
or erased automatically after 50 ignition cycles (key
ON-OFF cycles). The only fault that will not be
erased after 50 (KEY CYCLES) is the (CAB) fault.
The (CAB) fault can only be erased by using the
DRB II diagnostic tester. More than one fault can be
stored at a time. The number of key cycles since the
most recent fault was stored is also displayed. Most
functions of the (CAB) and (ABS) system can be ac-
cessed by the technician for testing and diagnostic
purposes by using the DRB II Diagnostic Tester.
START-UP CYCLE
The START-UP CYCLE takes place immediately
after the ignition switch is turned on. It is an elec-
trical check of basic electrical functions such as the
System Relay and Anti-Lock Warning Lamp Relay.
During this check, the Amber Anti-Lock Warning
Lamp is turned on, then turned off at the end of the
test. The test takes approximatel y1-2seconds to
complete.
5 - 92 ANTI-LOCK 10 BRAKE SYSTEM Ä

DRIVE-OFF CYCLE
The DRIVE-OFF CYCLE takes place when the ve-
hicle reaches about 3 miles per hour the first time af-
ter an ignition reset. During this test, the modulator
solenoid valves are activated briefly to test their
function. The DRIVE-OFF CYCLE will be bypassed
if you drive-off with the service brake pedal de-
pressed.
LATCHING VERSUS NON-LATCHING FAULTS
Some faults detected by the (CAB) are latching.
The fault is latched and (ABS) function is disabled
until the ignition switch is reset (turned OFF/ON).
Thus (ABS) function is disabled even if the original
fault has disappeared during the ignition cycle in
which it occurred. Other faults are non-latching; any
warning lights that are turned on are only on as long
as the fault condition exists. As soon as the condition
goes away. The Amber Anti-Lock Warning Light is
turned off. Although a fault code will be set in most
cases. (Example:low accumulator fault will not be
stored for a time of 2 minutes after the fault is de-
tected).
BENDIX ABS SYSTEMS DIAGNOSTICS
The Bendix Anti-Lock 10 Brake System diagnos-
tics. Beyond the basic mechanical diagnostics, sys-
tems and components covered earlier in this section,
is accomplished by using the DRB II diagnostic
tester. See testing procedures outlined in the Bendix
Anti-Lock 10 Diagnostics Manual for the 1993 M.Y. Please reference the above mentioned manual. For
any further diagnostic service procedures that are re-
quired on the Bendix Anti-Lock 10 Brake System, re-
quiring the use of the DRB II diagnostic tester.
ON CAR HYDRAULIC ABS COMPONENT SERVICE
WARNING: FAILURE TO FULLY DE-PRESSURIZE
THE HYDRAULIC ACCUMULATOR BEFORE PER-
FORMING HYDRAULIC SYSTEM SERVICE OPERA-
TIONS. COULD RESULT IN INJURY TO SERVICE
PERSONNEL AND OR DAMAGE TO PAINTED SUR-
FACES. SEE SECTION 2 FOR ADDITIONAL WARN-
INGS AND CAUTIONS.
GENERAL SERVICE PRECAUTIONS
The following are general precautions that should
be observed when servicing the Anti-Lock Brake Sys-
tem and/or other vehicle systems. Failure to observe
these precautions may result in Anti-Lock brake sys-
tem damage. If welding work is to be performed on the vehicle,
using an electric arc welder, the (CAB) connector
should be disconnected during the welding operation. The (CAB) or hydraulic assembly connector should
never be connected or disconnected with the ignition
switch in the ONposition.
Many components of the Anti-Lock brake system are
not serviceable and must be replaced as an assembly.
Do not attempt to disassemble any component
that is not designed to be a serviced component.
DE-PRESSURIZING HYDRAULIC ACCUMULA- TOR
The pump/motor assembly will keep the hydraulic
accumulator charged to approximately 11,032 and
13,790 kPa (1600 and 2000 psi) any time that the
ignition is in the ON position. The pump/motor assem-
bly cannot run if the ignition is off or if either battery
cable is disconnected. Unless otherwise specified, the hydraulic accumula-
tor should be de-pressurized before disassembling any
portion of the hydraulic system. The following proce-
dure should be used to relieve the pressure in the
hydraulic accumulator: (1) With ignition off, or either battery cable discon-
nected, pump the brake pedal a minimum of 40 times,
using approximately 222 N (50 lbs.) pedal force. A
noticeable change in pedal feel will occur, when the
accumulator is discharged. (2) When a definite increase in pedal effort is felt,
pump pedal a few additional times. This will insure
removal of all hydraulic pressure from the brake sys-
tem.
CHECKING BRAKE FLUID LEVEL
CAUTION: Use only brake fluid conforming to DOT 3
specifications such as Mopar Tor Equivalent. Do not
use any fluid in the brake hydraulic system, which
contains a petroleum base. Do not use a container
which has been used for petroleum based fluids or a
container that is wet with water. Petroleum based
fluids will cause swelling and distortion of rubber
parts in the hydraulic brake system and water will mix
with brake fluid, lowering the fluid boiling point. Keep
all brake fluid containers tightly capped to prevent
contamination.
The hydraulic assembly is equipped with a plastic
fluid reservoir, with a filter/strainer located in the filler
neck of each reservoir section. The Anti-Lock brake system requires that the hy-
draulic accumulator be de-pressurized when checking
the fluid level. To check the brake fluid level, the
following procedure should be used: (1) With the ignition off, de-pressurize the hydraulic
accumulator by applying the brake pedal approxi-
mately 40 times, using a pedal force of approximately
220 N (50 lbs.). A noticeable change in pedal feel will
occur when the accumulator is de-
Ä ANTI-LOCK 10 BRAKE SYSTEM 5 - 93

pressurized. When a definite increase in pedal effort
is felt, pump pedal a few additional times. This will
insure removal of all hydraulic pressure from the
brake system.(2) Thoroughly clean both reservoir caps and sur-
rounding area of reservoir before cap removal. This
will avoid getting dirt into the reservoir and brake
fluid. (3) Inspect the fluid level, see instructions on top
of reservoir (Fill To Top Of The White Screen In
Front Filter/Strainer). (4) Fill reservoir to top of white screen on filter/
strainer (Fig. 1) as required. Use only brake fluid
conforming to DOT 3 specifications such as Mopar t
or an Equivalent.
(5) Replace reservoir cap.
BLEEDING ABS BRAKE SYSTEM
The Anti-Lock brake system must be bled anytime
air is permitted to enter the brake hydraulic system,
due to disconnection of brake lines or hoses for ser-
vice. It is important to note that excessive air in the
brake system may set a primary pressure/delta P
fault in the (CAB). Refer to Diagnosis, for further in-
formation. Pressure bleeding or manual bleeding procedures
can be used when bleeding the (ABS) hydraulic sys-
tem, after brake lines or hoses have been discon-
nected. Bleeding the (ABS) hydraulic system is also
necessary after the replacement of the hydraulic as-
sembly or wheel brakes. During bleeding operations, be sure that the brake
fluid level remains close to the FULL level in the
reservoir. Check the fluid level periodically during the bleeding procedure and add only DOT 3 brake
fluid to the reservoir as required.
PRESSURE BLEEDING (FIG. 2)
The brake lines may be pressure bled, using a
standard diaphragm type pressure bleeder. Only dia-
phragm type pressure bleeding equipment should be
used to prevent air, moisture, and other contami-
nants from entering the system. The following proce-
dure should be used for pressure bleeding of the
master cylinder and wheel circuits (Fig. 2) (1) Ignition should be turned off and remain off
throughout this procedure. (2) Fully de-pressurize hydraulic accumulator by
pumping brake pedal a minimum of 40 times. The
procedure is fully described in this section of the ser-
vice manual under De-Pressurizing Hydraulic Accu-
mulator.
WARNING: FAILURE TO DE-PRESSURIZE HYDRAU-
LIC ACCUMULATOR, BEFORE PERFORMING THIS
OPERATION, MAY RESULT IN PERSONAL INJURY
AND/OR DAMAGE TO PAINTED SURFACES.
(3) Remove both reservoir caps (Fig. 2).
(4) Install pressure bleeder adapter, on front reser-
voir port and a dummy cap on the rear port of the
reservoir (Fig. 2) (5) Attach bleeding equipment to bleeder adapter
(Fig. 2). Charge pressure bleeder to approximately
138 kPa (20 psi).
(6) Connect a transparent hose to the caliper bleed
screw (Fig. 3). Submerge the free end of the hose in a
clear glass container, which is partially filled with
clean, fresh brake fluid.
Fig. 1 ABS Fill Level On Filter/Strainer
Fig. 2 Pressure Bleeding Brake System
5 - 94 ANTI-LOCK 10 BRAKE SYSTEM Ä

(7) With the pressure bleeder turned on, open the
caliper bleed screw 3/4 to one full turn allowing brake
fluid to flow into the container. Leave bleed screw open
until a clear, bubble-free flow of brake fluid is coming
from the hose in the container. If the reservoir has been
drained or the hydraulic assembly removed from the
car before the bleeding operation. Slowly pump the
brake pedal one or two times while the bleed screw is
open and fluid is flowing. This will help purge any
trapped air from the hydraulic assembly. Tighten
bleeder screw to 10 N Im (7.5 ft. lbs.) torque.
(8) Step 7 above should be done at all wheel brakes,
following the order wheel by wheel as listed below. a) Left rear.
b) Right rear.
c) Left front.
d) Right front.
(9) After bleeding is completed at all four wheel
brakes. Remove pressure bleeding equipment and
adapter by closing pressure bleeder valve and slowly
unscrewing bleeder adapter from hydraulic assembly
reservoir. Failure to release pressure in the reser-
voir will cause spillage of brake fluid, and could
result in personal injury or damage to painted
surfaces. (10) Using a syringe or equivalent method, remove
excess fluid from the reservoir to bring the brake fluid
to the required fill level (Fig. 1). If brake fluid is below
the proper level add Mopar tbrake fluid or equivalent
conforming to DOT 3, requirements. (11) Install the reservoir caps and turn on the igni-
tion to allow the (ABS) pump to charge the accumula-
tor.
MANUAL BLEEDING
Brake lines can be bled, using the manual bleeding
method. Manual bleeding is a two person operation,
one to pump the brake pedal and the other to bleed
each wheel brake. The following procedure should be
used: De-pressurizing the hydraulic accumulator is done
by following the steps described below. (1) Verify that the ignition switch is in the off posi-
tion. (2) Fully de-pressurize the hydraulic accumulator by
pumping brake pedal a minimum of 40 times. Use the
procedure as described in De-Pressurizing Hydraulic
Accumulator listed earlier in this section.
WARNING: FAILURE TO DE-PRESSURIZE HYDRAU-
LIC ACCUMULATOR, PRIOR TO PERFORMING THIS
OPERATION, MAY RESULT IN PERSONAL INJURY
AND/OR DAMAGE TO PAINTED SURFACES.
(3) Connect a transparent hose to the bleed screw on
the wheel cylinder or brake caliper that is to be bled (Fig. 3). Submerge the free end of the hose in a
clear glass container, which is partially filled with
clean, fresh brake fluid.
(4) Slowly pump the brake pedal several times,
using full strokes of the pedal and allowing approxi-
mately five seconds between pedal strokes. After two or
three strokes, continue to hold pressure on the pedal,
keeping it at the bottom of its travel. (5) With pressure on the pedal, open the bleed screw
3/4 to 1 full turn. Leave bleed screw open until fluid no
longer flows from the hose. Tighten the bleed screw
and release the pedal. Be sure that the bleed screw
it tightened before brake pedal is released, or air
may be drawn back into hydraulic system. (6) Repeat Steps 3, 4 and 5 on each wheel brake,
until clear, bubble-free fluid flows from the hose. (7) Repeat the above sequence at each wheel brake,
in the following order: a) Left rear.
b) Right rear.
c) Left front.
d) Right front.
(8) Fill the hydraulic assembly to the proper fill level
(Fig. 1) using Mopar tor equivalent brake fluid meet-
ing DOT 3, requirements. (9) Install both reservoir caps on reservoir.
(10) Turn the ignition switch to the RUN position to
allow the Pump/Motor to turn on and recharge the
accumulator.
Fig. 3 Bleeding Brake System
Ä ANTI-LOCK 10 BRAKE SYSTEM 5 - 95

(7) Install high pressure hose to hydraulic assem-
bly (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 hydrau-
lic 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
(Fig. 9). (See Checking Brake Fluid Level in this sec-
tion of the service manual).
BRAKE FLUID RESERVOIR
REMOVE
(1) Fully de-pressurize the hydraulic accumulator
by pumping brake pedal a minimum of 40 times. Use
procedure described in De-Pressurizing Hydraulic Ac-
cumulator 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 hydrau-
lic assembly.
(4) Using needle nose pliers, remove the three
fluid reservoir retaining pins from the hydraulic as-
sembly (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 hydrau-
Fig. 9 ABS Fill Level On Filter/Strainer
Fig. 10 Removing Bladder Accumulator
Fig. 11 Remove Reservoir Retaining Pins
Ä ANTI-LOCK 10 BRAKE SYSTEM 5 - 99

(8) Fill the hydraulic assembly reservoir to the top
of the screen on the filter/strainer (Fig. 15). Using
fresh clean brake fluid such as Mopar tor equivalent,
conforming to DOT 3 requirements.
PUMP SUPPLY FILTER
REMOVE
(1) Fully de-pressurize the hydraulic accumulator
by pumping brake pedal a minimum of 40 times. Use
procedure described in De-Pressurizing Hydraulic Ac-
cumulator 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 and then reinstall one filler cap from
brake fluid reservoir on hydraulic assembly. (3) Remove brake fluid supply hose from hydraulic
assembly master cylinder at the pump supply filter
(Fig. 16). After hose is removed from pump supply
filter, plug end of hose to stop brake fluid from drain-
ing out of fluid reservoir. (4) Remove brake fluid supply hose (Fig. 16), from
pump supply filter going to the pump motor assem-
bly. (5) Remove pump supply filter (Fig. 16) from at-
taching bracket on front of hydraulic assembly.
INSTALL (1) Attach pump supply filter to attaching bracket
on front of hydraulic assembly (Fig. 16). (2) Install replacement hose clamp, on brake fluid
supply hose to pump motor assembly. (3) Install the brake fluid supply hose to pump mo-
tor assembly, onto the nipple of the pump supply fil-
ter. Position hose clamp on brake fluid supply hose
so that it is past upset bead on nipple, then torque
hose clamp to 1.5 N Im (13.5 in. lbs.).
(4) Remove plug from brake fluid supply hose com-
ing from hydraulic assembly. Install the brake fluid
supply hose from hydraulic assembly, onto the nipple
of the pump supply filter. Position hose clamp on
brake fluid supply hose so that it is past upset bead
on nipple, then torque hose clamp to 1.5 N Im (13.5
in. lbs.). (5) Turn ignition switch to the run position to en-
ergize the pump/motor assembly and pressurize hy-
draulic system. Check for leakage at the hydraulic
assembly to hydraulic bladder accumulator fitting. (6) Again de-pressurize accumulator by pumping
brake pedal a minimum of 40 times as described. Use
procedure in De-Pressurizing Hydraulic Accumulator
in this section of the manual. (7) Then check the brake fluid level in the hydrau-
lic assembly reservoir. If brake fluid level is low, fill
reservoir to proper level (Fig. 15) with Mopar tbrake
fluid or equivalent conforming to DOT 3 require-
ments.
HYDRAULIC BLADDER ACCUMULATOR
REMOVE
(1) Fully de-pressurize the hydraulic accumulator
by pumping brake pedal a minimum of 40 times. Use
procedure described in De-Pressurizing Hydraulic Ac-
cumulator listed earlier in this section.
Fig. 15 ABS Reservoir Fill Level On Filter/Strainer
Fig. 16 Pump Supply Filter
Ä ANTI-LOCK 10 BRAKE SYSTEM 5 - 101