1996 CHRYSLER VOYAGER Egr

(15) Remove the EGR Valve and the vacuum
transducer (Fig. 125) as an assembly from the intake
manifold.
(16) Disconnect vacuum hose from check valve
located on vacuum booster.DO NOT REMOVE
CHECK VALVE FROM POWER BRAKE
BOOSTER.
(17) Locate the vacuum booster input rod to brake
pedal connection under the instrument panel. Posi-
tion a small screwdriver between the center tang on
the power brake booster input rod to brake pedal pin
retaining clip (Fig. 126).
(18) Rotate screwdriver enough to allow retaining
clip center tang to pass over end of brake pedal pin.
Then pull retaining clip off brake pedal pin.Discard
retaining clip. It is not to be reused. Replace
only with a new retaining clip when assem-
bling.
(19) Remove the 4 nuts attaching the power brake
vacuum booster to the dash panel. Nuts are accessi-ble from under dash panel in area of the steering col-
umn and pedal bracket assembly.
(20) From outside the vehicle, slide power brake
vacuum booster forward until its mounting studs
clear dash panel. Then tilt the booster up and toward
the center of vehicle to remove.
CAUTION: Do not attempt to disassemble the
power brake vacuum booster it is to be serviced
ONLY as a complete assembly.
INSTALL
CAUTION: When installing the power brake vacuum
booster in the vehicle be sure the heater hoses do
not become trapped between the booster and the
dash panel of the vehicle.
(1) Position vacuum booster on dash panel using
the reverse procedure of its removal.
(2) Install the 4 nuts mounting the vacuum
booster to the dash panel. Tighten the 4 mounting
nuts to a torque of 29 N´m (250 in. lbs.).
(3) Using lubriplate, or an equivalent, coat the sur-
face of the brake pedal pin where it contacts the vac-
uum booster input rod.
CAUTION: When installing the brake pedal pin on
the power brake vacuum booster input rod, do not
re-use the old retaining clip.
(4) Install vacuum booster input rod on brake
pedal pin and install aNEWretaining clip (Fig. 127).
(5) Connect the vacuum hose on the check valve in
the power brake vacuum booster.
(6) Install EGR Valve and vacuum transducer (Fig.
125) on the intake manifold. Install and tighten the 2
EGR valve mounting bolts to a torque of 22 N´m (200
in. lbs.).
Fig. 125 EGR Valve Attachment To Intake Manifold
Fig. 126 Vacuum Booster Input Rod Retaining Pin
Fig. 127 Retaining Pin Installed On Brake Pedal Pin
5 - 54 BRAKESNS
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)

(4) Insert cable housing retainer into body outrig-
ger bracket making certain that cable housing
retainer fingers lock the housing firmly into place.
(5) Connect rear park brake cable to the equalizer
bracket (Fig. 169).
(6) Install brake drum, and wheel and tire assem-
bly.
(7) Remove the locking pliers from the front park
brake cable. This will automatically adjust the park
brake cables.
(8) Apply and release park brake pedal 1 time,
this will seat the park brake cables.
STOP LAMP SWITCH
REMOVE
(1) Depress and hold the brake pedal while rotat-
ing stop lamp switch (Fig. 172) in a counter-clockwise
direction approximately 30 degrees.
(2) Pull the switch rearward and remove from its
mounting bracket.
(3) Disconnect wiring harness connector from stop
lamp switch.
INSTALL
NOTE: Prior to installing stop lamp switch into
bracket, the plunger must be moved to its fully
extended position using procedure in Step 1.
(1) Hold stop lamp switch firmly in one hand.
Then using other hand, pull outward on the plunger
of the stop lamp switch until it has ratcheted out to
its fully extended position.
(2) Connect the wiring harness connector to the
stop lamp switch.
(3) Mount the stop lamp switch into the bracket
using the following procedure. Depress the brake
pedal as far down as possible. Then install switch in
bracket by aligning index key on switch with slot attop of square hole in mounting bracket. When switch
is fully installed in bracket, rotate switch clockwise
approximately 30É to lock switch into bracket.
CAUTION: Do not use excessive force when pulling
back on brake pedal to adjust the stop lamp switch.
If to much force is used, damage to the stop lamp
switch or striker (Fig. 172) can result.
(4) Gently pull back on brake pedal until the pedal
stops moving. This will cause the switch plunger to
ratchet backward to the correct position.
DISASSEMBLY AND ASSEMBLY
MASTER CYLINDER TO POWER BRAKE BOOSTER
VACUUM SEAL
(1) Remove the master cylinder from the power
brake vacuum booster. Refer to Master Cylinder
removal, for the required procedure to remove master
cylinder from power brake vacuum booster.
(2) Using a soft tool such as a trim stick, remove
the vacuum seal from the master cylinder mounting
flange.
(3) Using Mopar Brake Parts Cleaner or an equiv-
alent, thoroughly clean end of master cylinder hous-
ing and master cylinder push rod.
(4) Install new master cylinder to power brake
booster vacuum seal on master cylinder.When
installing new vacuum seal, be sure it is
squarely seated against master cylinder mount-
ing flange and in groove of push rod (Fig. 173).
(5) Bleed the master cylinder assembly prior to
installing it on the power brake vacuum booster.
(6) Install master cylinder assembly on the power
brake vacuum booster. Refer to Master Cylinder
Installation for the required procedure to install the
master cylinder on the power brake vacuum booster.
Fig. 172 Stop Lamp Switch
Fig. 173 Vacuum Seal Installed On Master Cylinder
NSBRAKES 5 - 69
REMOVAL AND INSTALLATION (Continued)

ANTILOCK BRAKE SYSTEM ± TEVES MARK-20
INDEX
page page
DESCRIPTION AND OPERATION
ABS BRAKE SYSTEM COMPONENTS........ 87
ABS BRAKES COMPONENT
ABBREVIATION LIST.................... 85
ABS BRAKES OPERATION AND VEHICLE
PERFORMANCE....................... 86
ABS FUSES............................ 89
ABS MASTER CYLINDER AND POWER
BRAKE BOOSTER..................... 87
ABS RELAYS........................... 89
ABS WARNING LAMP (YELLOW)............ 91
ANTILOCK BRAKES OPERATION
DESCRIPTION........................ 85
ASR VALVE (ABS WITH TRACTION
CONTROL ONLY)...................... 88
CONTROLLER ANTILOCK BRAKES (CAB)..... 90
HCU BRAKE FLUID ACCUMULATORS AND
NOISE DAMPING CHAMBER............. 88
HCU PUMP/MOTOR..................... 89
HYDRAULIC CIRCUITS AND VALVE
OPERATION.......................... 92
INLET VALVES AND SOLENOIDS............ 88
INTEGRATED CONTROL UNIT (ICU)......... 87
OUTLET VALVES AND SOLENOIDS.......... 88
PROPORTIONING VALVES................ 89
WHEEL SPEED SENSORS................. 89
DIAGNOSIS AND TESTING
ABS BRAKE DIAGNOSTIC TOOL
CONNECTOR......................... 96
ABS DIAGNOSTIC TROUBLE CODES........ 97
ABS DIAGNOSTICS MANUAL.............. 96ABS GENERAL DIAGNOSTICS
INFORMATION........................ 95
ABS SERVICE PRECAUTIONS.............. 99
ABS SYSTEM SELF DIAGNOSTICS.......... 96
ABS WIRING DIAGRAM INFORMATION....... 95
BRAKE FLUID CONTAMINATION............ 98
DRB DIAGNOSTIC SCAN TOOL USAGE...... 96
INTERMITTENT DIAGNOSTIC TROUBLE
CODES.............................. 97
PROPORTIONING VALVE................. 98
TEST DRIVING ABS COMPLAINT VEHICLE.... 98
TONEWHEEL INSPECTION................ 98
SERVICE PROCEDURES
BLEEDING TEVES MARK 20 HYDRAULIC
SYSTEM............................. 99
BRAKE FLUID LEVEL INSPECTION.......... 99
REMOVAL AND INSTALLATION
ABS GENERAL SERVICE PRECAUTIONS.... 100
CONTROLLER ANTILOCK BRAKES (CAB).... 103
HYDRAULIC CONTROL UNIT.............. 100
TONE WHEEL (REAR AWD)............... 111
TONE WHEEL (REAR FWD)............... 110
WHEEL SPEED SENSOR (FRONT)......... 105
WHEEL SPEED SENSOR (REAR AWD)...... 108
WHEEL SPEED SENSOR (REAR FWD)...... 106
SPECIFICATIONS
BRAKE FASTENER TORQUE
SPECIFICATIONS..................... 112
SPEED SENSOR TONE WHEEL RUNOUT.... 112
WHEEL SPEED SENSOR TO TONE
WHEEL CLEARANCE.................. 112
DESCRIPTION AND OPERATION
ANTILOCK BRAKES OPERATION DESCRIPTION
The purpose of an Antilock Brake System (ABS) is to
prevent wheel lock-up under braking conditions on virtu-
ally any type of road surface. Antilock Braking is desirable
because a vehicle which is stopped without locking the
wheels will retain directional stability and some steering
capability. This allows the driver to retain greater control
of the vehicle during braking.
This section of the service manual covers the description
and on car service for the ITT Teves Mark 20 ABS Brake
System and the ITT Teves Mark 20 ABS Brake System
with Traction Control. If other service is required on the
non ABS related components of the brake system, refer to
the appropriate section in this group of the service manual
for the specific service procedure required.
ABS BRAKES COMPONENT ABBREVIATION LIST
In this section of the service manual, several
abbreviations are used for the components of the
Teves Mark 20 ABS Brake System and the Teves
Mark 20 ABS Brake System with Traction Control.
They are listed below for your reference.
²CAB±Controller Antilock Brake
²ICU±Integrated Control Unit
²HCU±Hydraulic Control Unit
²TCS±Traction Control
²ABS±Antilock Brake System
²PSI±Pounds Per Square Inch (pressure)
²WSS±Wheel Speed Sensor
²FWD±Front Wheel Drive
²AWD±All Wheel Drive
²DTC±Diagnostic Trouble Code
NSBRAKES 5 - 85

PREMATURE ABS CYCLING
NOTE: When working on a vehicle which has a
complaint of premature ABS cycling it may be nec-
essary to use a DRB Scan Tool to detect and verify
the condition.
There is one complaint called Premature ABS
Cycling in which neither the Red Brake Warning
Lamp nor the Amber Antilock Lamp were illumi-
nated and no fault codes were stored in the CAB.
Symptoms of Premature ABS Cycling, include click-
ing sounds from the solenoids valves, pump motor
running and pulsations in the brake pedal. This con-
dition can occur at any braking rate of the vehicle
and on any type of road surface. This creates an
additional condition which needs to be correctly
assessed when diagnosing problems with the antilock
brake system.
The following conditions are common causes that
need to be checked when diagnosing a condition of
Premature ABS Cycling. Damaged tone wheels,
incorrect tone wheels, damage to a wheel speed sen-
sor mounting boss on a steering knuckle, a loose
wheel speed sensor mounting bolt, and excessive tone
wheel runout. Also, an excessively large tone wheel
to wheel speed sensor air gap can lead to the condi-
tion of Premature ABS Cycling. Special attention is
to be given to these components when diagnosing a
vehicle exhibiting the condition of Premature ABS
Cycling. After diagnosing the defective component,
repair or replace as required.
When the component repair or replacement is com-
pleted, test drive the vehicle to verify the condition of
Premature ABS Cycling has been corrected.
ABS BRAKE SYSTEM COMPONENTS
The following is a detailed description of the Teves
Mark 20 ABS brake system components. For infor-
mation on servicing the base brake system compo-
nents, see the base Brake System section of this
Service Manual.
ABS MASTER CYLINDER AND POWER BRAKE
BOOSTER
A vehicle equipped with Teves Mark 20 ABS
without optional traction control uses the same
type of a master cylinder and power brake
booster (Fig. 1) as a vehicle not equipped with
antilock brakes.
A vehicle equipped with Teves Mark 20 ABS
with Traction control uses a unique center port
master cylinder. If the master cylinder is
replaced on a vehicle equipped with traction
control be sure the right type of master cylin-
der is installed.A vehicle equipped with four wheel disc
brakes (AWD applications) also have a unique
master cylinder. The master cylinder used on
these vehicles have a piston bore diameter
which is larger then the master cylinder used
on the other brake applications.
The primary and secondary outlet ports on the
master cylinder go directly to the hydraulic control
unit HCU.
Reference the appropriate section of this service
manual for further information on the individual
components.
INTEGRATED CONTROL UNIT (ICU)
The hydraulic control unit (HCU) (Fig. 2) used
with the Teves Mark 20 ABS is different from the
HCU used on previous Chrysler products with ABS.
The HCU used on this ABS system is part of the
integrated contol unit (ICU). The HCU is part of
what is referred to as the ICU because the HCU and
the controller antilock brakes (CAB) are combined
(integrated) into one unit. This differs from previous
Chrysler products with ABS, where the HCU and the
CAB were separate components located in different
areas of the vehicle.
Teves Mark 20 ABS uses two different HCU's and
CAB's depending on the type of ABS system the vehi-
cle is equipped with. There is a unique HCU and
CAB for a vehicle equipped with just ABS and a
unique HCU and CAB for a vehicle equipped with
ABS and traction control.
NOTE: The HCU and CAB used on a vehicle that is
equipped with only ABS and on a vehicle that is
equipped with ABS and traction control are differ-
ent. The HCU on a vehicle equipped with ABS and
traction control has a valve block housing (Fig. 2)
that is approximately 1 inch longer on the low pres-
sure fluid accumulators side than a HCU for a vehi-
cle that is equipped with only ABS.
Fig. 1 Master Cylinder And Vacuum Booster
NSBRAKES 5 - 87
DESCRIPTION AND OPERATION (Continued)

The front wheel speed sensor is attached to a boss
in the steering knuckle (Fig. 7). The front tone wheel
(Fig. 7) is part of the driveshafts outboard constant
velocity joint. The rear wheel speed sensor ismounted through the rear axle, rear brake support
plate and directly to the rear bearing (Fig. 8) (Fig. 9).
The rear tone wheel on a front wheel drive vehicle is
an integral part of the rear wheel hub/bearing
assembly. If damaged though, the rear tone wheel on
a front wheel drive vehicle can be replaced as a indi-
vidual component of the rear hub/bearing assembly.
Refer to Rear Tone Wheel in the Remove And Install
Section in this group of the service manual for the
required procedure. The wheel speed sensor air gap
is NOT adjustable.
The rear tone wheel on a all wheel drive vehicle, is
part of the outboard constant velocity joint on the
rear driveshaft (Fig. 9).
The four wheel speed sensors are all serviced indi-
vidually, but the front tone wheel on all vehicles and
the rear tone wheel on all wheel drive vehicles are
serviced as part of the front or rear driveshaft out-
board constant velocity joint (Fig. 7) and (Fig. 9).
Correct ABS system operation is dependent on
accurate wheel speed signals. The vehicle's wheels
and tires must all be the same size and type to gen-
erate accurate signals. Variations in wheel and tire
size can produce inaccurate wheel speed signals,
which can cause false ABS cycles to occur.
CONTROLLER ANTILOCK BRAKES (CAB)
The Controller Antilock Brakes (CAB) is a micro-
processor based device which monitors the ABS sys-
tem during normal braking and controls it when the
vehicle is in an ABS stop. The CAB is mounted to the
bottom of the HCU (Fig. 10). The CAB uses a 25 way
electrical connector on the vehicle wiring harness.
The power source for the CAB is through the ignition
switch in the Run or On position.THE (CAB) IS ON
THE CCD BUS
Fig. 6 Proportioning Valve Mounting Location
Fig. 7 Front Wheel Speed Sensor
Fig. 8 Rear Wheel Speed Sensor (FWD)
Fig. 9 Rear Wheel Speed Sensor (AWD)
5 - 90 BRAKESNS
DESCRIPTION AND OPERATION (Continued)

(7) Install wheel lug nuts on 3 of the wheel mount-
ing studs to protect the stud threads from damage by
the vise jaws. Mount the hub/bearing assembly in a
vise (Fig. 50). Using Puller, Special Tool C-4693
installed as shown in (Fig. 50) remove the tone wheel
from the hub/bearing assembly.
INSTALL
(1) Place hub/bearing assembly in an arbor press
supported by Receiver, Special Tool, 6062A±3 (Fig.
51). Position Driver, Special Tool 6908±1 with under-
cut side facing up (Fig. 51) on top of the tone wheel.
(2) Press the tone wheel onto the hub/bearing
assembly until it is flush with the end of hub shaft
(Fig. 52).
(3) Install the 4 hub/bearing to axle flange mount-
ing bolts into the 4 mounting holes in the flange of
the rear axle.(4) Install the rear brake support plate on the 4
mounting bolts installed in the flange of the rear
axle.
(5) Align the rear hub/bearing assembly with the 4
mounting bolts and start mounting bolts into hub/
bearing assembly. Tighten the 4 bolts in a criss-cross
pattern until the hub/bearing and brake support
plate is fully and squarely seated onto flange of rear
axle.
(6) Tighten the 4 hub/bearing mounting bolts (Fig.
48) to a torque of 129 N´m (95 ft. lbs.)
(7) Install the rear wheel speed sensor on the rear
hub/bearing flange (Fig. 47). Install the speed sensor
attaching bolt and tighten to a torque of 12 N´m (105
in. lbs.).
(8) Check the air gap between the face of the
wheel speed sensor and the top surface of the tone-
wheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (.047 in.).
(9) Install the brake drum onto the rear hub/bear-
ing assembly.
(10) Install rear wheel and tire assembly, tighten
wheel stud nuts to 129 N´m (95 ft. lbs.).
(11) Adjust the rear brakes, (See Adjusting Service
Brakes) in Service Adjustments section in this group
of the service manual.
TONE WHEEL (REAR AWD)
The rear tone wheel on all wheel drive applications
is an integral part of each rear axle outer C/V joint.
If the rear tone wheel on an all wheel drive vehicle
requires replacement it can not be replace as a sep-
arate component of the rear axle. Tone wheel replace-
ment will require the replacement of the rear axle.
Refer to Differential And Driveline in this service
manual for the rear axle replacement procedure.
Fig. 50 Tone Wheel Removal From Hub/Bearing
Assembly
Fig. 51 Installing Tone Wheel On Hub/Bearing
Assembly
Fig. 52 Correctly Installed Tone Wheel
NSBRAKES 5 - 111
REMOVAL AND INSTALLATION (Continued)

The clutch pedal on the 2.0L is fitted with a return
spring (Fig. 3). The spring hook that attaches to the
pedal is coated with nylon. Push the hook all the way
through the hole in the pedal to prevent it from
walking out. No service lubrication is required.
The clutch pedal on the 2.4L and 2.5L VM diesel is
fitted with an assist spring (Fig. 4) to reduce clutch
pedal effort. The assist spring has two plastic end fit-
tings which locate to pins on the clutch pedal and
bracket. The plastic which the fittings are made of
includes PTFE lubricant. No service lubrication is
required.
HYDRAULIC LINKAGE AND COMPONENTS Ð
RHD
The hydraulic clutch linkage is a prefilled system
free of air, contamination, and leaks. There is no rou-
tine maintenance required. The hydraulic clutch link-
age is serviced as an assembly and the individual
components cannot be overhauled or serviced sepa-
rately. The hydraulic linkage consists of a clutch
master cylinder with integral reservoir, a clutch slave
cylinder and an interconnecting fluid line with quick
disconnect coupling (Fig. 5).
The clutch master cylinder push rod is connected
to the clutch pedal (Fig. 6). The clutch pedal is fitted
with a return spring. The spring hook that attaches
to the pedal is coated with nylon. No service lubrica-
tion is necessary. The slave cylinder push rod is con-
nected to the clutch release fork (Fig. 5).
Fig. 2 Clutch Pedal Components Ð LHD
Fig. 3 Clutch Pedal Return Spring Ð 2.0L LHD
Fig. 4 Assist Spring Ð 2.4L and 2.5L VM Diesel LHD
6 - 2 CLUTCHNS/GS
GENERAL INFORMATION (Continued)