1996 CHRYSLER VOYAGER drain bolt

CAUTION: Corrosion may occur between the hub/
bearing and the axle. If this occurs the hub/bearing
will be difficult to remove from the axle. If the hub/
bearing will not come out of the axle by pulling on
it by hand, do not pound on the hub/bearing to
remove it from the axle. Pounding on the hub/bear-
ing to remove it from the axle will damage the hub/
bearing. This damage will result in noise or failure
of the bearing.
(8) If hub/bearing cannot be removed from the axle
by hand, use Remover Special Tool 8214 (Fig. 76) and
following procedure to press the hub/bearing out of
the axle.
(a) Place Special Tool 8214-1 over tone wheel
and against cast flange of hub/bearing (Fig. 76)
(b) Put a dab of grease in the bolt pilot hole on
the back of Special Tool 8214-1.
(c) Insert Special Tool 8214-2 into the hole in the
bottom of the end casting on the axle (Fig. 76).
Special Tool 8214-2 should be against and sup-
ported by the axle plate (Fig. 76) when pressing
the wheel bearing out of the axle.If Special Tool
8214-2 will not fit into the hole in the end
casting, file or grind the flashing from the
hole until tool fits properly.
(d) Align bolt in Special Tool 8214-2 with pilot
hole in Special Tool 8214-1. Tighten bolt against
Special Tool 8214-1.
(e) Press hub/bearing out of axle by continuing
to tighten bolt in Special Tool 8214-2 against Spe-
cial Tool 8214-1.
(9) Remove the hub/bearing from the rear axle and
brake support plate (Fig. 77).
(10) Using a suitable tool such as a 14 mm box
wrench (Fig. 78) or an aircraft type hose clamp, com-
press the flared legs on park brake cable retainer.
Then pull the park brake cable out of brake support
plate.(11) Lower vehicle enough to access the brake
pedal.
(12) Using a brake pedal depressor, move brake
pedal to a position past its first 1 inch of travel. This
will prevent brake fluid from draining out of master
cylinder when brake tube is remove from wheel cyl-
inder.
(13) Raise vehicle.
(14) Disconnect brake tube from wheel cylinder
(Fig. 79).
(15) Remove the 2 bolts attaching the wheel cylin-
der to the brake support plate (Fig. 79).
(16) Remove the wheel cylinder from the brake
support plate.
(17) Remove the rear brake support plate from the
rear axle.
Fig. 76 Special Tool 8214 Installed
Fig. 77 Hub/Bearing Removal And Installation On
Axle
Fig. 78 Removing Park Brake Cable From Brake
Support Plate
5 - 38 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

CAUTION: When installing the primary and second-
ary brake tubes on master cylinder, be sure brake
tubes do not contact any other components within
the vehicle and that there is slack in the flexible
sections of the tubes. This is required due to the
movement between the ABS hydraulic control mod-
ule (HCU) and the master cylinder, when the vehicle
is in motion.
(4) Connect the primary and secondary brake
tubes to master cylinder primary and secondary
ports (Fig. 99). Brake tubes must be held securely
when tightened to control orientation of flex section.
Then fully tighten the tube nuts to a torque of 17
N´m (145 in. lbs.).
(5) Install the vehicle wiring harness connector, on
the brake fluid level sensor in the master cylinder
brake fluid reservoir (Fig. 98).
(6) Install filler tube into the master cylinder fluid
reservoir (Fig. 97).
VACUUM BOOSTER 2.4 LITER ENGINE
REMOVE
CAUTION: Reserve vacuum in the vacuum booster
must be pumped down (removed) before removing
master cylinder from vacuum booster. This is nec-
essary to prevent the vacuum booster from sucking
in any contamination as the master cylinder is
removed. This can be done simply by pumping 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 (4-5 strokes).
(2) Remove both battery cables from battery.
(3) Remove the battery thermal guard and the bat-
tery from the battery tray.
(4) Remove the air inlet resonator and hoses as an
assembly from the throttle body and air cleaner
housing (Fig. 104)
(5) If vehicle is equipped with speed control,
unplug wiring harness connector from the speed con-
trol servo. Then disconnect vacuum lines from the
speed control servo and vacuum reservoir on battery
tray.
(6) Remove bolt attaching the speed control servo
bracket to the battery tray. Slide the bracket forward
to unhook it from the battery tray and remove.
(7) Remove the 2 bolts and the nut (Fig. 105)
attaching the battery tray to the body.
(8) Remove wiring harness connector from brake
fluid level sensor in master cylinder fluid reservoir
(Fig. 106).
(9) Clean the area where the master cylinder
assembly attaches to the power brake booster. Useonly a solvent such as Mopar Brake Parts Cleaner or
an equivalent.
(10) Remove clip attaching drain hose for wiper
module to brake tube at master cylinder. Remove
Fig. 104 Air Inlet Resonator
Fig. 105 Battery Tray Mounting Locations
Fig. 106 Fluid Level Sensor Electrical Connection
NSBRAKES 5 - 47
REMOVAL AND INSTALLATION (Continued)

(7) Install aNEWvacuum seal on mounting flange
of master cylinder (Fig. 110).
(8) Position master cylinder on studs of vacuum
booster aligning push rod on vacuum booster with
master cylinder piston.
(9) Install the 2 nuts (Fig. 107) mounting the mas-
ter cylinder to the vacuum booster. Tighten the
mounting nuts to a torque of 25 N´m (225 in. lbs.).
(10) Install the wiper module drain hose (Fig. 107)
on the wiper module. Install the tie strap attaching
the wiper module drain hose to the brake tube at the
master cylinder.Tie strap should be loosely tight-
ened so as not to collapse the wiper module
drain hose.
(11) Install the wiring harness connector on the
brake fluid level sensor in the master cylinder fluid
reservoir (Fig. 106).
(12) Install the battery tray in the vehicle. Install
the 2 bolts and the nut (Fig. 105) attaching the bat-
tery tray. Tighten the 2 bolts and the nut to a torque
of 14 N´m (125 in lbs.).(13) If vehicle is equipped with speed control,
install the speed control servo and bracket on the
battery tray. Install and securely tighten bolt attach-
ing bracket to battery tray.
(14) If vehicle is equipped with speed control,
install the wiring harness connector on the speed
control servo. Then connect the vacuum lines onto
the speed control servo and vacuum reservoir on bat-
tery tray.
(15) Install the air inlet resonator and hoses as an
assembly on the throttle body and air cleaner hous-
ing (Fig. 104). Securely tighten the hose clamp at the
air cleaner housing and throttle body.
(16) Install the battery and the battery thermal
guard.
(17) Install the battery cables on the battery.
(18) Check the operation of the stop lamp switch
and adjust if necessary.
VACUUM BOOSTER 3.0 LITER ENGINE
REMOVE
CAUTION: Stored vacuum in the vacuum booster
must be pumped down (removed) before removing
master cylinder from power brake booster. This is
necessary 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 the brake
pedal until a firm pedal is achieved (4-5 strokes).
(2) Remove both battery cables from battery.
(3) Remove the battery thermal guard and the bat-
tery from the battery tray.
(4) Remove the air inlet resonator and hoses as an
assembly from the throttle body and air cleaner
housing (Fig. 111)
(5) If vehicle is equipped with speed control,
unplug wiring harness connector from the speed con-
trol servo. Then disconnect vacuum lines from the
speed control servo and vacuum reservoir on battery
tray.
(6) Remove bolt attaching the speed control servo
bracket to the battery tray. Slide the bracket forward
to unhook it from the battery tray and remove.
(7) Remove the 2 bolts and the nut (Fig. 112)
attaching the battery tray to the body of the vehicle.
(8) Remove wiring harness connector from brake
fluid level sensor in master cylinder fluid reservoir
(Fig. 113).
(9) Clean the area where the master cylinder
assembly attaches to the power brake booster. Use
only a solvent such as Mopar Brake Parts Cleaner or
an equivalent.
Fig. 109 Retaining Clip Installed On Brake Pedal Pin
Fig. 110 Vacuum Seal Installed On Master Cylinder
NSBRAKES 5 - 49
REMOVAL AND INSTALLATION (Continued)

CAUTION: The master cylinder is used to create
the seal for holding vacuum in the vacuum booster.
The vacuum seal on the master cylinder MUST be
replaced with a NEW seal whenever the master cyl-
inder is removed from the vacuum booster.
CAUTION: When removing the vacuum seal from
the master cylinder do not use a sharp tool.
(7) Using a soft tool such as a trim stick, remove
the vacuum seal from the master cylinder mounting
flange.
(8) Install aNEWvacuum seal on mounting flange
of the master cylinder (Fig. 128).
(9) Position master cylinder on studs of vacuum
booster, aligning push rod on vacuum booster with
master cylinder piston.
(10) Install the 2 nuts mounting the master cylin-
der to the vacuum booster (Fig. 124). Tighten both
mounting nuts to a torque of 25 N´m (225 in. lbs.).
(11) Install the wiper module drain hose (Fig. 124)
on the wiper module. Install the tie strap attaching
the wiper module drain hose to brake tube at the
master cylinder.Tie strap should be loosely tight-
ened so as not to collapse the wiper module
drain hose.
(12) Install the wiring harness connector on the
brake fluid level sensor in the master cylinder fluid
reservoir (Fig. 123).
(13) Install the throttle body and throttle cable
bracket on the intake manifold. Install the 2 bolts
(Fig. 122) attaching the throttle body to the intake
manifold and tighten to a torque of 25 N´m (225 in.
lbs.) Install clip (Fig. 122) attaching the wiring har-
ness to the throttle cable bracket.
(14) Install the wiring harness connectors on the
throttle position sensor and the AIS motor on throttle
body (Fig. 121).(15) Install the wiring harness connector (Fig. 120)
on the EGR valve transducer.
(16) Install the battery tray. Install the 2 bolts and
the nut (Fig. 119) attaching the battery tray to the
vehicle. Tighten the 2 bolts and the nut to a torque of
14 N´m (125 in lbs.).
(17) If vehicle is equipped with speed control,
install the speed control servo and bracket on the
battery tray. Install and securely tighten bolt attach-
ing bracket to battery tray.
(18) If vehicle is equipped with speed control,
install the wiring harness connector on the speed
control servo. Then connect the vacuum lines onto
the speed control servo and vacuum reservoir on bat-
tery tray.
(19) Install the air inlet resonator and hoses as an
assembly on the throttle body and air cleaner hous-
ing (Fig. 118). Securely tighten hose clamp at air
cleaner housing and throttle body.
(20) Install the battery and the battery thermal
guard.
(21) Install the battery cables on the battery.
(22) Check the operation of the stop lamp switch
and adjust if necessary.
JUNCTION BLOCK
REMOVE
(1) Using a brake pedal depressor, move and lock
the brake pedal to a position past its first 1 inch of
travel. This will prevent brake fluid from draining
out of the master cylinder when the brake tubes are
removed from the junction block.
(2) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication And Mainte-
nance Group of this service manual.
CAUTION: Before removing the brake tubes from
the junction block, the junction block and the brake
tubes must be thoroughly cleaned. This is required
to prevent contamination from entering the brake
hudraulic system.
(3) Remove the 6 chassis brake tubes (Fig. 129)
from the junction block.
(4) Remove the bolt (Fig. 130) attaching the junc-
tion block mounting braket to the front suspension
cradle.
INSTALL
(1) Install the junction block and mounting bracket
(Fig. 130) on the front suspension cradle. Install the
attaching bolt and tighten to a torque of 28 N´m (250
in. lbs.).
(2) Install the 6 chassis brake tubes (Fig. 131) into
the inlet and outlet ports of the junction block.
Fig. 128 Vacuum Seal Installed On Master Cylinder
NSBRAKES 5 - 55
REMOVAL AND INSTALLATION (Continued)

Tighten all 6 tube nuts to a torque of 16 N´m (145 in.
lbs.).
(3) Bleed the brake system thoroughly to ensure
that all air has been expelled from the hydraulic sys-tem. See Bleeding Brake System in the Service
Adjustments section in this group of the service man-
ual for the proper bleeding procedure.
(4) Lower the vehicle.
(5) Road test the vehicle to verify proper operation
of the vehicles brake system.
PROPORTIONING VALVE (W/ABS BRAKES)
The actual proportioning valves of the proportion-
ing valve assembly are not serviceable or replaceable.
If a proportioning valve of the proportioning valve
assembly is not functioning properly, the fixed pro-
portioning valve must be replaced as an assembly.
REMOVE
(1) Using a brake pedal depressor, move and lock
the brake pedal to a position past its first 1 inch of
travel. This will prevent brake fluid from draining
out of the master cylinder when the brake tubes are
removed from the proportioning valve.
(2) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication And Mainte-
nance Group of this service manual.
CAUTION: Before removing the brake tubes from
the proportioning valve, the proportioning valve and
the brake tubes must be thoroughly cleaned. This is
required to prevent contamination from entering the
proportioning valve or the brake tubes.
(3) Remove the 4 chassis brake lines from the inlet
and outlet ports of the proportioning valve (Fig. 132).
(4) Remove the bolts (Fig. 133) attaching the pro-
portioning valve bracket to the frame rail of the vehi-
cle. Remove the fixed proportioning valve assembly
from the vehicle.
Fig. 129 Junction Block Brake Tubes
Fig. 130 Junction Block Mounting
Fig. 131 Brake Tube Connections To Junction Block
Fig. 132 Chassis Brake Tubes At Proportioning
Valve
5 - 56 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

INSTALL
CAUTION: When mounting the original or a
replacement proportioning valve on the frame rail of
the vehicle install the mounting bolts in only the
two forward holes of the mounting bracket (Fig.
133).
(1) Install proportioning valve assembly on the
frame rail of the vehicle. Install the proportioning
valve assembly attaching bolts (Fig. 133). Tighten the
attaching bolts to a torque of 14 N´m (125 in. lbs.).
(2) Install the 4 chassis brake lines (Fig. 132) into
the inlet and outlet ports of the proportioning valve
assembly. Tighten all 4 line nuts to a torque of 16
N´m (142 in. lbs.).
(3) Bleed the brake system thoroughly enough to
ensure that all air has been expelled from the
hydraulic system. See Bleeding Brake System in the
Service Adjustments section in this group of the ser-
vice manual for the proper bleeding procedure.
(4) Lower the vehicle to the ground.
(5) Road test the vehicle to verify proper operation
of the vehicles brake system.
PROPORTIONING VALVE (W/O ABS BRAKES)
The components of the proportioning valve assem-
bly are not serviceable or replaceable. If a component
of the proportioning valve assembly is not function-
ing properly, the proportioning valve must be
replaced as an assembly.
REMOVE
(1) Using a brake pedal depressor, move and lock
the brake pedal to a position past its first 1 inch of
travel. This will prevent brake fluid from draining
out of the master cylinder when the brake tubes are
removed from the proportioning valve.(2) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication And Mainte-
nance Group of this service manual.
CAUTION: Before removing the brake tubes from
the proportioning valve, the proportioning valve and
the brake tubes must be thoroughly cleaned. This is
required to prevent contamination from entering the
proportioning valve or the brake tubes.
(3) Remove the 4 chassis brake tubes from the
inlet and outlet ports of the proportioning valve (Fig.
134).
(4) Remove the 2 bolts (Fig. 135) attaching the
proportioning valve to the proportioning valve
mounting bracket. Remove the proportioning valve
from the mounting bracket.
(5) Remove the hooked end of the proportioning
valve actuator (Fig. 136) from the isolator bushing on
the lever of the height proportioning valve (Fig. 136).
Fig. 133 Proportioning Valve Attachment To Vehicle
Fig. 134 Chassis Brake Tubes At Proportioning
Valve
Fig. 135 Proportioning Valve Mounting
NSBRAKES 5 - 57
REMOVAL AND INSTALLATION (Continued)

CONTROLLER ANTILOCK BRAKES (CAB)
REMOVE
(1) Disconnect the negative (ground) cable from
the battery and isolate cable.
(2) Using a brake pedal depressor, move and lock
the brake pedal to a position past the first inch of
pedal travel.This will prevent brake fluid from
draining out of the master cylinder when the
brake tubes are removed from the HCU.
(3) Raise vehicle. Vehicle is to be raised and sup-
ported on jackstands or on a frame contact type
hoist. See Hoisting in the Lubrication And Mainte-
nance section of this service manual.
CAUTION: Do not apply a 12 volt power source to
any terminals of the 25 way HCU connector when
disconnected.
(4) Remove the 25 way connector (Fig. 25) from
the CAB located on the bottom of the HCU. The 25
way connector is removed from the CAB using the
following procedure. Grasp the lock on the 25 way
connector (Fig. 25) and pull it as far out as possible
(Fig. 26). This will unlock and raise the 25 way con-
nector from the socket on the CAB.
CAUTION: Before removing the brake tubes from
the HCU, the HCU must be thoroughly cleaned. This
must be done to prevent dirt particles from falling
into the ports of HCU or entering the brake tubes.
(5) Thoroughly clean all surfaces of the HCU, and
all brake tube nuts located on the HCU. Use only a
solvent such as Mopar Brake Parts Cleaner or an
equivalent to clean the HCU.
(6) Remove the brake tubes (6) from the inlet and
outlet ports on the HCU. (Fig. 27).(7) Remove the 3 bolts (Fig. 28) attaching the
HCU mounting bracket to the front suspension cross-
member.
Fig. 25 CAB 25 Way Connector
Fig. 26 Unlocking CAB 25 Way Connector
Fig. 27 Brake Tube Connections To HCU
Fig. 28 HCU To Suspension Cradle Mounting Bolts
NSBRAKES 5 - 103
REMOVAL AND INSTALLATION (Continued)

Continue filling system until full, this provides bet-
ter heater performance.Be careful not to spill
coolant on drive belts or the generator.
Fill coolant reserve system to at least the MAX
mark with 50/50 solution. It may be necessary to add
coolant to the reserve tank after three or four warm
up/cool down cycles to maintain coolant level between
the MAX and MIN mark. This will allow trapped air
to be removed from the system.
REMOVAL AND INSTALLATION
WATER PUMPÐ2.4L ENGINE
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on a hoist. Remove right inner
splash shield.
(3) Remove accessory drive belts. Refer to Acces-
sory Drive Belt service in this section.
(4) Drain cooling system. Refer to Cooling System
Draining in this section.
(5) Support engine from the bottom and remove
right engine mount.
(6) Remove right engine mount bracket.
(7) Remove timing belt. Refer to Group 9, Engine
for procedure.
(8) Remove timing belt idler pulley.
(9) Hold camshaft sprocket with Special tool
C-4687 and adaptor C-4687-1 while removing bolt.
Remove both cam sprockets.
(10) Remove rear timing belt cover.
(11) Remove water pump attaching screws to
engine (Fig. 16).
INSTALLATION
(1) Install new O-ring gasket in water pump body
O-ring groove (Fig. 17).
CAUTION: Make sure O-ring is properly seated in
water pump groove before tightening screws. An
improperly located O-ring may cause damage to the
O-ring and cause a coolant leak.(2) Assemble pump body to block and tighten
screws to 12 N´m (105 in. lbs.) (Fig. 16). Pressurize
cooling system to 15 psi with pressure tester and
check water pump shaft seal and O-ring for leaks.
(3) Rotate pump by hand to check for freedom of
movement.
(4) Install rear timing belt cover.
(5) Install camshaft sprockets and torque bolts to
101 N´m (75 ft. lbs.).
(6) Install timing belt idler pulley and torque
mounting bolt to 61 N´m (45 ft. lbs.).
(7) Install timing belt. Refer to Group 9, Engine,
2.4L Timing Belt.
(8) Install right engine mount bracket and engine
mount. Refer to Group 9 for procedure.
(9) Fill cooling system. SeeCooling System Fill-
ing.
(10) Install accessory drive belts, Refer to Acces-
sory Drive Belts, in this section.
(11) Lower vehicle and connect battery cable.
WATER PUMP INLET TUBEÐ2.4L ENGINE
REMOVAL
(1) Drain cooling system. Refer to procedure out-
lined in this section.
(2) Remove upper radiator hose to access the hose
connections at the inlet tube.
(3) Remove lower radiator hose and heater hose
from the inlet tube (Fig. 18).
(4) Remove the 2 fasteners that hold the inlet
tube to the block.
(5) Rotate tube while removing the tube from the
engine block (Fig. 19).
INSTALLATION
(1) Inspect the O-ring for damage before installing
the tube into the cylinder block (Fig. 19).
(2) Lube O-ring with coolant and install into the
cylinder block opening.
(3) Install 2 fasteners and tighten to 12 N´m (105
in. lbs.).
(4) Connect lower radiator hose and heater hose
to inlet tube (Fig. 18).
Fig. 16 Water PumpÐ2.4L Engine
Fig. 17 Water Pump Body
NSCOOLING SYSTEM 7 - 17
SERVICE PROCEDURES (Continued)