1996 CHRYSLER VOYAGER wiring

START-UP CYCLE
The self diagnostic ABS start up cycle begins when
the ignition switch is turned to the on position. Elec-
trical checks are completed on ABS components, such
as the Controller, solenoid continuity, and the system
relay operation. During this check the Amber ABS
Warning Light is turned on for approximately 4 sec-
onds and the brake pedal may emit a popping sound
and move slightly when the solenoid valves are
checked.
DRIVE-OFF CYCLE
Further Functional testing is accomplished once
the vehicle is set in motion and reaches a speed of
about 20 kph (12 mph.). This cycle is performed only
once after each ignition on/off cycle.
²The pump/motor is activated briefly to verify
function. When the pump/motor is activated a whirl-
ing or buzzing sound may be heard by the driver,
which is normal when the pump/motor is running.
²The wheel speed sensor output is verified to be
within the correct operating range.
ONGOING TESTS
Other tests are performed on a continuous basis.
These include checks for solenoid continuity, wheel
speed sensor continuity and wheel speed sensor out-
put.
ABS DIAGNOSTIC TROUBLE CODES
Diagnostic trouble codes (DTC) are kept in the con-
troller's memory until either erased by the technician
using the DRB or erased automatically after 3500
miles. DTC's are retained by the controller even if
the ignition is turned off or the battery is discon-
nected. More than one DTC can be stored at a time.
The mileage of the most recent occurrence, number of
occurrences and the DTC that was stored is also dis-
played. Most functions of the CAB and the ABS sys-
tem can be accessed by the technician for testing and
diagnostic purposes by using the DRB.
LATCHING VERSUS NON-LATCHING
DIAGNOSTIC TROUBLE CODES
Some DTC's detected by the CAB are latching; the
DTC is latched and ABS braking is disabled until the
ignition switch is reset. Thus ABS braking is non
operational even if the original DTC has disappeared.
Other DTC's are non-latching; any warning lights
that are turned on, are only turned on as long as the
DTC condition exists. As soon as the condition goes
away, the ABS Warning Light is turned off, although
a DTC will be set in most cases.
INTERMITTENT DIAGNOSTIC TROUBLE CODES
As with virtually any electronic system, intermit-
tent electrical problems in the ABS system may be
difficult to accurately diagnose.
Most intermittent electrical problems are caused
by faulty electrical connections or wiring. When an
intermittent fault is encountered, check suspect cir-
cuits for:
A visual inspection for loose, disconnected, or mis-
routed wires should be done before attempting to
diagnose or service the ITT Teves Mark 20 antilock
brake system. A visual inspection will eliminate
unnecessary testing and diagnostics time. A thorough
visual inspection will include the following compo-
nents and areas of the vehicle.
(1) Inspect fuses in the power distribution center
(PDC) and the wiring junction block. Verify that all
fuses are fully inserted into the PDC and wring junc-
tion block. A label on the underside of the PDC cover
identifies the locations of the ABS fuses in the PDC.
(2) Inspect the 25-way electrical connector at the
CAB for damage, spread or backed-out wiring termi-
nals. Verify that the 25-way connector is fully
inserted in the socket on the CAB. Be sure that wires
are not stretched tight or pulled out of the connector.
(3) Verify that all the wheel speed sensor connec-
tions are secure.
(4) Poor mating of connector halves or terminals
not fully seated in the connector body.
(5) Improperly formed or damaged terminals. All
connector terminals in a suspect circuit should be
carefully reformed to increase contact tension.
(6) Poor terminal to wire connection. This requires
removing the terminal from the connector body to
inspect.
(7) Pin presence in the connector assembly
(8) Proper ground connections. Check all ground
connections for signs of corrosion, tight fasteners, or
other potential defects. Refer to wiring diagram man-
ual for ground locations.
(9) Problems with main power sources of the vehi-
cle. Inspect battery, generator, ignition circuits and
other related relays and fuses.
(10) If a visual check does not find the cause of the
problem, operate the car in an attempt to duplicate
the condition and record the trouble code.
(11) Most failures of the ABS system will disable
ABS function for the entire ignition cycle even if the
fault clears before 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 inter-
mittent illumination of the ABS Warning Lamp. All
other failures will cause the lamp to remain on until
the ignition switch is turned off. Circuits involving
NSBRAKES 5 - 97
DIAGNOSIS AND TESTING (Continued)

Before test driving a brake complaint vehicle, note
whether the Red or Amber Brake Warning Lamp is
turned on. If it is the Red Brake Warning Lamp,
refer to the hydraulic system section in the brake
group of this manual. If the ABS Warning lamp
was/is on, test drive the vehicle as described below, to
verify the complaint. While the ABS Warning Lamp
is on, the ABS is not functional. The standard brake
system and the ability to stop the car may not be
affected if only the ABS Warning Lamp is on.
Discuss with the owner of the vehicle or note any
other electrical problems or conditions that may be
occurring on the vehicle. They may have an effect on
the antilock brake system's function.
(1) Turn the key to the off position and then back
to the on position. Note whether the ABS Warning
Lamp continues to stay on. If it does, refer to the
diagnostic manual covering the ITT Teves Mark 20
ABS system for the required test procedures.
(2) If the ABS Warning Lamp goes out, shift into
gear and drive the car to a speed of 20 kph (12 mph)
to complete the ABS start up cycle. If at this time the
ABS Warning Lamp goes on refer to the ITT Teves
Mark 20 Diagnostic Manual.
(3) If the ABS Warning Lamp remains OUT, drive
the vehicle a short distance. During this test drive be
sure that the vehicle achieves at least 40 mph. Brake
to at least one complete stop in an ABS cycle, and
again accelerate to 25 mph.
(4) If a functional problem with the ABS system is
determined while test driving a vehicle, refer to the
diagnostic manual covering the ITT Teves Mark 20
ABS system for the required test procedures and
proper use of the DRB diagnostic scan tool.
ABS SERVICE PRECAUTIONS
The ABS uses an electronic control module, the
CAB. This module is designed to withstand normal
current draws associated with vehicle operation.
Care must be taken to avoid overloading the CAB
circuits.In testing for open or short circuits, do
not ground or apply voltage to any of the cir-
cuits unless instructed to do so for a diagnostic
procedure.These circuits should only be tested
using a high impedance multi-meter or the DRB
tester as described in this section. Power should
never be removed or applied to any control module
with the ignition in the ON position. Before removing
or connecting battery cables, fuses, or connectors,
always turn the ignition to the OFF position.
CAUTION: Use only factory wiring harnesses. Do
not cut or splice wiring to the brake circuits. The
addition of after-market electrical equipment (car
phone, radar detector, citizen band radio, trailer
lighting, trailer brakes, ect.) on a vehicle equippedwith antilock brakes may affect the function of the
antilock brake system.
SERVICE PROCEDURES
BRAKE FLUID LEVEL INSPECTION
CAUTION: Use only Mopar brake fluid or an equiv-
alent from a tightly sealed container. Brake fluid
must conform to DOT 3 specifications. Do not use
petroleum-based fluid because seal damage in the
brake system will result.
For the specific procedure covering the inspection
of the brake fluid level and adding brake fluid to the
reservoir, refer to the Service Adjustments Section in
this group of the service manual.
BLEEDING TEVES MARK 20 HYDRAULIC SYSTEM
The base brake system must be bled anytime air is
permitted to enter the hydraulic system, due to dis-
connection of brake lines, hoses or components. The
ABS system, particularly the HCU, should only be
bled when the HCU is replaced or removed from the
vehicle, or if there is reason to believe the HCU has
ingested air. Under most circumstances that would
require brake bleeding, only the base brake system
needs to be bled.
It is important to note that excessive air in the
brake system will cause a soft or spongy feeling
brake pedal.
During bleeding operations, be sure that the brake
fluid level remains close to the FULL level in the res-
ervoir. Check the fluid level periodically during the
bleeding procedure and add DOT 3 brake fluid as
required.
The Teves Mark 20 ABS hydraulic system and the
base brake hydraulic system must be bled as two
independent braking systems. The non ABS portion
of the brake system is to be bled the same as any
non ABS system. Refer to the Service Adjustments
section in this manual for the proper bleeding proce-
dure to be used. This brake system can be either
pressure bled or manually bled.
The ABS portion of the brake system MUST be
bled separately. This bleeding procedure requires the
use of the DRB Diagnostic Tester and the bleeding
sequence procedure outlined below.
ABS BLEEDING PROCEDURE
When bleeding the ABS system, the following
bleeding sequenceMUSTbe followed to insure com-
plete and adequate bleeding. The ABS system can be
bled using a manual bleeding procedure or standard
pressure bleeding equipment.
NSBRAKES 5 - 99
DIAGNOSIS AND TESTING (Continued)

hoist. See Hoisting in the Lubrication And Mainte-
nance section of this service manual.
(4) Remove the routing clip attaching the HCU
wiring harness to the HCU mounting bracket (Fig.
19).
CAUTION: Do not apply a 12 volt power source to
any terminals of the 25 way HCU connector when
disconnected.
(5) Remove the 25 way connector (Fig. 19) from
the CAB. The 25 way connector is removed from the
CAB using the following procedure. Grasp the lock
on the 25 way connector (Fig. 19) and pull it as far
out as possible (Fig. 20). This will raise and unlock
the 25 way connector 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.(6) 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.
(7) Remove the brake tubes (6) from the inlet and
outlet ports on the HCU. (Fig. 21).
(8) Remove the 3 bolts (Fig. 22) attaching the
HCU mounting bracket to the front suspension cross-
member.
(9) Remove HCU and the mounting bracket as a
unit from the vehicle.
(10) Remove the 3 bolts (Fig. 23) mounting the
HCU to the mounting bracket. Separate the HCU
from the mounting bracket.
(11) Remove the CAB (Fig. 19) from the bottom of
the HCU for installation on the replacement HCU.
Refer to Controller Antilock Brakes (CAB) in the
Removal And Installation Section in this group of the
service manual for the required procedure.
Fig. 19 CAB 25 Way Connector
Fig. 20 Unlocked 25 Way CAB Connector
Fig. 21 Brake Tube Connections To HCU
Fig. 22 HCU To Suspension Cradle Mounting Bolts
NSBRAKES 5 - 101
REMOVAL AND INSTALLATION (Continued)

INSTALL
(1) Install the CAB (Fig. 19) on the bottom of the
HCU. Refer to Controller Antilock Brakes (CAB) in
the Removal And Installation Section in this group of
the service manual for the required procedure.
(2) Install the HCU on the mounting bracket (Fig.
23). Install the 3 bolts (Fig. 23) attaching the HCU to
the mounting bracket. Tighten the 3 mounting bolts
to a torque of 11 N´m (97 in. lbs.).
CAUTION: The HCU mounting bracket to front sus-
pension cradle mounting bolts have a unique corro-
sion protection coating and a special aluminum
washer. For this reason, only the original, or origi-
nal equipment Mopar replacement bolts can be
used to mount the HCU bracket to the front suspen-
sion crossmember.
(3) Install the HCU and its mounting bracket as
an assembly on the front suspension crossmember.
Install the 3 bolts attaching the HCU bracket to the
crossmember (Fig. 22). Tighten the 3 mounting bolts
to a torque of 28 N´m (250 in. lbs.).
CAUTION: Because of the flexible section in the
primary and secondary brake tubes, and the brake
tubes between the HCU and the proportioning
valve, the brake tubes must be held in proper ori-
entation when tightened and torqued. These tubes
must not contact each other or other vehicle com-
ponents when installed. Also, after the brake tubes
are installed on the HCU, ensure all spacer clips are
reinstalled on the brake tubes.
CAUTION: When installing the chassis brake tubes
on the HCU valve block, they must be located cor-
rectly in the valve block to ensure proper ABS oper-
ation. Refer to (Fig. 21) for the correct chassis
brake tube locations.NOTE: The chassis brake tube attachment loca-
tions to the HCU, are marked on the bottom of the
HCU mounting bracket.
(4) Install the 6 chassis brake tubes into their cor-
rect port locations on the HCU valve block as shown
in (Fig. 21). Tighten the tube nuts to a torque of 17
N´m (145 in. lbs.).
NOTE: Before installing the 25 way connector in
the CAB be sure the seal is properly installed in the
connector.
(5) Install the 25 way connector (Fig. 19) on the
CAB using the following procedure. Position the 25
way connector in the socket of the CAB and carefully
push it down as far as possible. When connector is
fully seated by hand into the CAB socket, push in the
connector lock (Fig. 20). This will pull the connector
into the socket of the CAB and lock it in the installed
position.
NOTE: The CAB wiring harness must be clipped to
the HCU mounting bracket. This will ensure the wir-
ing harness is properly routed and does not contact
the brake tubes or the body of the vehicle.
(6) Clip the cab wiring harness (Fig. 19) to the
HCU mounting bracket.
(7) Install the routing clips (Fig. 24) on the brake
tubes.
(8) Lower vehicle.
(9) Connect negative cable back on negative post of
the battery.
(10) Bleed the base brakes and the ABS brakes
hydraulic system. Refer to the Bleeding ABS System
in this section of the manual for the proper bleeding
procedure.
(11) Road test vehicle to ensure proper operation of
the base and ABS systems.
Fig. 23 HCU Mounting Bolts
Fig. 24 Brake Tube Routing Clips
5 - 102 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

(8) Remove HCU and the mounting bracket as a
unit from the vehicle.
(9) Remove the 3 bolts (Fig. 29) mounting the
HCU to the mounting bracket. Separate the HCU
from the mounting bracket.
(10) Unplug the pump motor wiring harness (Fig.
30) from the CAB.
(11) Remove the 4 bolts (Fig. 31) attaching the
CAB to the valve block of the HCU.
(12) Remove the CAB from the valve block of the
HCU (Fig. 32).
INSTALL
(1) Install the CAB (Fig. 32) on the valve block of
the HCU.
(2) Install the 4 bolts mounting the CAB (Fig. 31)
to the valve block of the HCU. Tighten the CAB
mounting bolts to a torque of 2 N´m (17 in. lbs.).
(3) Plug the pump/motor wiring harness into the
CAB (Fig. 30).(4) Install the HCU on the mounting bracket (Fig.
29). Install the 3 bolts (Fig. 29) attaching the HCU to
the mounting bracket. Tighten the 3 mounting bolts
to a torque of 11 N´m (97 in. lbs.).
CAUTION: The HCU mounting bracket to front sus-
pension cradle mounting bolts have a unique corro-
sion protection coating and a special aluminum
washer. For this reason, only the original, or origi-
nal equipment Mopar replacement bolts can be
used to mount the HCU bracket to the front suspen-
sion crossmember.
(5) Install the HCU and its mounting bracket as
an assembly on the front suspension crossmember.
Install the 3 bolts attaching the HCU bracket to the
crossmember (Fig. 28). Tighten the 3 mounting bolts
to a torque of 28 N´m (250 in. lbs.).
Fig. 29 HCU Mounting Bolts
Fig. 30 Pump Motor To CAB Wiring Harness
Fig. 31 CAB Attaching Bolts
Fig. 32 Remove/Install CAB
5 - 104 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

CAUTION: Because of the flexible section in the
primary and secondary brake tubes, and the brake
tubes between the HCU and the proportioning
valve, the brake tubes must be held in proper ori-
entation when tightened and torqued. These tubes
must not contact each other or other vehicle com-
ponents when installed.
CAUTION: When installing the chassis brake tubes
on the HCU valve block, they must be located cor-
rectly in the valve block to ensure proper ABS oper-
ation. Refer to (Fig. 27) for the correct chassis
brake tube locations.
NOTE: The chassis brake tube attachment loca-
tions to the HCU, are marked on the bottom of the
HCU mounting bracket.
(6) Install the 6 chassis brake tubes into their cor-
rect port locations on the HCU valve block as shown
in (Fig. 27). Tighten the tube nuts to a torque of 17
N´m (145 in. lbs.).
NOTE: Before installing the 25 way connector in
the CAB be sure the seal is properly installed in the
connector.
(7) Install the 25 way connector on the CAB using
the following procedure. Position the 25 way connec-
tor in the socket of the CAB and carefully push it
down as far as possible. When connector is fully
seated by hand into the CAB socket, push in the con-
nector lock (Fig. 26). This will pull the connector into
the socket of the CAB and lock it in the installed
position.
(8) Install the routing clips (Fig. 33) on the brake
tubes.(9) Lower vehicle.
(10) Connect negative cable back on negative post
of the battery.
(11) Bleed the base brakes and the ABS brakes
hydraulic system. Refer to the Bleeding ABS System
in this section of the manual for the proper bleeding
procedure.
(12) Road test vehicle to ensure proper operation
of the base and ABS brake systems.
WHEEL SPEED SENSOR (FRONT)
REMOVE
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this service man-
ual, for the required lifting procedure to be used for
this vehicle.
(2) Remove the tire and wheel assembly from the
vehicle.
(3) Remove the 2 screws (Fig. 34) attaching front
channel bracket and grommet retainer to the outer
frame rail.
CAUTION: When disconnecting the wheel speed
sensor from vehicle wiring harness, be careful not
to damage pins on connector
(4) Pull speed sensor cable grommet and connector
through the hole in the strut tower (Fig. 35). Discon-
nect speed sensor cable from vehicle wiring harness
(Fig. 35).
(5) Remove the wheel speed sensor head to steer-
ing knuckle attaching bolt (Fig. 36).
(6) Remove sensor head from steering knuckle. If
the sensor has seized, due to corrosion,DO NOT
USE PLIERS ON SENSOR HEAD.Use a hammer
and a punch and tap edge of sensor ear, rocking the
sensor side to side until free.
Fig. 33 Brake Tube Routing Clips
Fig. 34 Front Speed Sensor Cable Channel Bracket
NSBRAKES 5 - 105
REMOVAL AND INSTALLATION (Continued)

(7) Remove the wheel speed sensor cable grommets
from the retaining bracket (Fig. 37).(8) Remove front wheel speed sensor assembly
from the vehicle.
INSTALL
CAUTION: Proper installation of wheel speed sen-
sor cables is critical to continued system operation.
Be sure that cables are installed in retainers. Fail-
ure to install cables in retainers as shown in this
section may result in contact with moving parts
and/or over extension of cables, resulting in an
open circuit.
(1) Connect the front wheel speed sensor cable to
the vehicle wiring harness connector (Fig. 35). Be
sure speed sensor cable connector is fully seated and
locked into vehicle wiring harness connector, then
insert cable and grommet into hole in strut tower
(Fig. 35).
CAUTION: When installing channel bracket, do not
pinch the speed sensor cable under the channel
bracket.
(2) Install the channel bracket and grommet
retainer on the frame rail (Fig. 34).
(3) Install the 2 bolts (Fig. 34) attaching the chan-
nel bracket to frame. Tighten the 2 attaching bolts to
a torque of 11 N´m (95 in. lbs.).
(4) Insert speed sensor cable grommets into inter-
mediate bracket on strut (Fig. 37). Route cable from
strut to steering knuckle on the rearward side of the
stabilizer bar link.
(5) Install the wheel speed sensor to steering
knuckle attaching bolt (Fig. 36). Tighten the speed
sensor attaching bolt to a torque of 12 N´m (105 in.
lbs.)
(6) 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.).
(7) Install the wheel and tire assembly on vehicle.
(8) Road test vehicle to ensure proper operation of
the base and ABS brake systems.
WHEEL SPEED SENSOR (REAR FWD)
REMOVE
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
(2) Remove the tire and wheel assembly from the
vehicle.
Fig. 35 Speed Sensor Cable To Vehicle Wiring
Harness
Fig. 36 Front Wheel Speed Sensor Attaching Bolt
Fig. 37 Front Wheel Speed Sensor Cable Routing
5 - 106 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

CAUTION: When unplugging speed sensor cable
from vehicle wiring harness be careful not to dam-
age pins on the electrical connectors. Also inspect
connectors for any signs of previous damage.
(3) Remove grommet from floor pan of vehicle and
unplug speed sensor cable connector from vehicle
wiring harness (Fig. 38).
CAUTION: When removing rear wheel speed sen-
sor cable from routing clips on rear brake flex hose,
be sure not to damage the routing clips. Routing
clips are molded onto the hose and will require
replacement of the brake flex hose if damaged dur-
ing removal of the speed sensor cable.
(4) Carefully remove the speed sensor cable from
the rear brake flex hose routing clips (Fig. 39).
(5) If removing the right rear speed sensor cable,
remove the speed sensor cable grommet from theaxle flange, the brake tube clip and the routing clip
from the track bar bracket on the axle (Fig. 40).
(6) Remove the 2 rear wheel speed sensor cable/
brake tube routing clips (Fig. 41). Then un-clip the
speed sensor cable from the routing clips on rear
brake tube (Fig. 41).
CAUTION: If the speed sensor has seized, due to
corrosion, do not use pliers on speed sensor head
in a attempt to remove it. Use a hammer and a
punch and tap edge of sensor, rocking the sensor
from side to side until free.
(7) Remove the wheel speed sensor head to rear
bearing attaching bolt (Fig. 42). If sensor head does
not come loose, do not use pliers. Tap with screw
driver and hammer.
(8) Remove the wheel speed sensor head from the
rear bearing assembly.
(9) Remove speed sensor assembly from vehicle.
Fig. 38 Rear Speed Sensor Cable Connection To
Vehicle Wiring Harness
Fig. 39 Speed Sensor Cable Attachment To Brake
Flex Hose
Fig. 40 Right Rear Speed Sensor Cable Routing
Fig. 41 Rear Speed Sensor Routing Brackets And
Clips
NSBRAKES 5 - 107
REMOVAL AND INSTALLATION (Continued)