1996 CHRYSLER VOYAGER park assist

BRAKE ACTUATION SYSTEM
ACTUATION:
Vacuum Operated Power Brakes.........Standard
Hydraulic System...........Dual-Diagonally Split
Antilock Brake Sytem (Teves Mark-20)...........
MASTER CYLINDER ASSEMBLY:
Supplier..............................Bosch
Type For Non-ABSAnd
ABS Brakes. . . .Conventional Compensating Port
Type For ABS Brakes
With Traction Control . . .Dual Center Port Design
Body Material...............Anodized Aluminum
Reservoir Material................Polypropelene
MASTER CYLINDER BORE /
STROKE AND SPLIT:
ABS W/Disc/Drum Brakes......23.8 mm x 36 mm
(.937 in. x 1.47 in.)
AWD W/Disc/Disc Brakes........25.4 mm x 39 mm
(1.00 in. x 1.50 in.)
Displacement Split.....................50/50
MASTER CYLINDER FLUID OUTLET PORTS:
Non-ABS And ABS . . .Primary 7/16±24 Secondary 7/
16±24
ABS With Traction Control.......Primary M12 x 1
Secondary M12 x 1
Outlet Fitting Type Non-ABS
AndABS...........Double Wall Inverted Flare
Outlet Fitting Type ABS With
Traction Control...................ISO Flare
ABS HYDRAULIC CONTROL UNIT:
Hydraulic Tube Fitting Type............ISO Flare
BOOSTER:
Make/Type.................Bosch Vacuum Assist
Mounting Studs.....................M8x1.25
Type .........................270 ZLT RSMV
Boost At 20 inches Of
Manifold Vacuum...........3800 N´m (850 lbs.)
PROPORTIONING VALVE:
Material...........................Aluminum
Function....................Hydraulic Pressure
Proportioning To Rear Brakes
BRAKE PEDAL
Pedal Ratio.............................3.36
BRAKE FASTENER TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
BRAKE TUBES:
Tube Nuts To Fittings And
Components..............17N´m(145 in. lbs.)
BRAKE HOSE:
To Caliper Banjo Bolt..........48N´m(35ft.lbs.)
Intermediate Bracket.........12N´m(105 in. lbs.)
MASTER CYLINDER:
To Vacuum Booster
Mounting Nut............25N´m(225 in. lbs.)
FIXED PROPORTIONING VALVE:
To Frame Rail Attaching
Bolts....................14N´m(125 in. lbs.)
HEIGHT SENSING PROPORTIONING VALVE:
To Mounting Bracket
Attaching Bolts...........23N´m(200 in. lbs.)
Actuator Assembly
Adjustment Nut.............5N´m(45in.lbs.)
Mounting Bracket To Frame
Rail Bolts................17N´m(150 in. lbs.)
JUNCTION BLOCK (NON-ABS BRAKES)
To Suspension Cradle
Mounting Bolt............28N´m(250 in. lbs.)
VACUUM BOOSTER:
To Dash Panel Mounting
Nuts....................28N´m(250 in. lbs.)
REAR WHEEL CYLINDER:
To Support Plate Mounting
Bolts.....................8N´m(75in.lbs.)
Bleeder Screw...............10N´m(80in.lbs.)
BRAKE SUPPORT PLATE:
To Rear Axle Mounting Bolts . . .130 N´m (95 ft. lbs.)
DISC BRAKE CALIPER:
Guide Pin Bolts..............41N´m(30ft.lbs.)
Bleeder Screw..............15N´m(125 in. lbs.)
ABS HYDRAULIC CONTROL UNIT:
Mounting Bracket To
Suspension Cradle Bolts.....28N´m(250 in. lbs.)
To Mounting Bracket Isolator
Attaching Bolts............11N´m(97in.lbs.)
CAB To HCU Mounting Screws . . .2 N´m (17 in. lbs.)
WHEEL SPEED SENSOR:
To Axle Or Steering Knuckle
Mounting Bolt............12N´m(105 in. lbs.)
PARKING BRAKE:
Pedal Assembly Mounting
Bolts....................28N´m(250 in. lbs.)
REAR HUB AND BEARING:
To Axle Mounting Bolts........129 N´m (95 ft. lbs.)
WHEEL:
Stud Lug Nut........115±156 N´m (84-115 ft. lbs.)
NSBRAKES 5 - 83
SPECIFICATIONS (Continued)

TEVES MARK 20 ABS WITH TRACTION
CONTROL± TRACTION CONTROL HYDRAULIC
CIRCUIT ± SOLENOID AND SHUTTLE VALVE
FUNCTION
This hydraulic circuit diagram (Fig. 16) shows a
vehicle equipped with ABS and traction control in
the traction control mode. The hydraulic circuit (Fig.
16) shows a situation where a driven wheel is spin-
ning and brake pressure is required to reduce its
speed. The normally open ASR valve (Fig. 16) is ener-
gized to isolate the brake fluid being pumped from
the master cylinder and to isolate the driven wheel.
Also, the normally open ASR valve bypasses the
pump output back to the master cylinder at a fixed
pressure setting. The normally open and normally
closed valves (Fig. 16) modulate the brake pressure
as required to the spinning wheel.
DIAGNOSIS AND TESTING
ABS GENERAL DIAGNOSTICS INFORMATION
This section contains the information necessary to
diagnose the ITT Teves Mark 20 ABS Brake System.
Specifically, this section should be used to help diag-
nose conditions which result in any of the following:
(1) ABS Warning Lamp turned on.(2) Brakes Lock-up on hard application
Diagnosis of base brake conditions which are obvi-
ously mechanical in nature should be directed to
Group 5 Brakes in this service manual. This includes
brake noise, brake pulsation, lack of power assist,
parking brake, Red BRAKE Warning Lamp lighting,
or vehicle vibration during normal braking.
Many conditions that generate customer com-
plaints may be normal operating conditions, but are
judged to be a problem due to not being familiar with
the ABS system. These conditions can be recognized
without performing extensive diagnostic work, given
adequate understanding of the operating principles
and performance characteristics of the ABS. See the
ABS System Operation Section in this group of the
service manual to familiarize yourself with the oper-
ating principles of the ABS system.
ABS WIRING DIAGRAM INFORMATION
During the diagnosis of the antilock brake system
it may become necessary to reference the wiring dia-
grams covering the antilock brake system and its
components. For wiring diagrams refer to Antilock
Brakes in Group 8W of this service manual. This
group will provide you with the wiring diagrams and
the circuit description and operation information cov-
ering the antilock brake system.
Fig. 15 ABS With Traction Control ABS Braking Hydraulic Circuit
NSBRAKES 5 - 95
DESCRIPTION AND OPERATION (Continued)

BATTERY OPEN CIRCUIT VOLTAGE TEST
An open circuit voltage no load test shows the
state of charge of a battery and whether it is ready
for a load test at 50 percent of the battery's cold
crank rating. Refer to Battery Load Test. If a battery
has open circuit voltage reading of 12.4 volts or
greater, and will not pass the load test, replace the
battery because it is defective. To test open circuit
voltage, perform the following operation.
(1) Remove both battery cables, negative cable
first. Battery top, cables and posts should be clean. If
green dot is not visible in indicator, charge the bat-
tery. Refer to Battery Charging Procedures.
(2) Connect a Volt/Ammeter/Load tester to the bat-
tery posts (Fig. 6). Rotate the load control knob of the
Carbon pile rheostat to apply a 300 amp load. Apply
this load for 15 seconds to remove the surface charge
from the battery, and return the control knob to off
(Fig. 7).
(3) Allow the battery to stabilize for 2 minutes,
and then verify the open circuit voltage (Fig. 9).
(4) This voltage reading will approximate the state
of charge of the battery. It will not reveal battery
cranking capacity. Refer to Battery Open Circuit
Voltage table.
SERVICE PROCEDURES
BATTERY CHARGING
WARNING: DO NOT CHARGE A BATTERY THAT
HAS EXCESSIVELY LOW ELECTROLYTE LEVEL.
BATTERY MAY SPARK INTERNALLY AND
EXPLODE. EXPLOSIVE GASES FORM OVER THE
BATTERY. DO NOT SMOKE, USE FLAME, OR CRE-
ATE SPARKS NEAR BATTERY. DO NOT ASSIST
BOOST OR CHARGE A FROZEN BATTERY. BAT-
TERY CASING MAY FRACTURE. BATTERY ACID IS
POISON, AND MAY CAUSE SEVERE BURNS. BAT-
TERIES CONTAIN SULFURIC ACID. AVOID CON-
TACT WITH SKIN, EYES, OR CLOTHING. IN THE
EVENT OF CONTACT, FLUSH WITH WATER AND
CALL PHYSICIAN IMMEDIATELY. KEEP OUT OF
REACH OF CHILDREN.
CAUTION: Disconnect the battery NEGATIVE cable
first. (Fig. 4) before charging battery to avoid dam-
age to electrical systems. Do not exceed 16.0 volts
while charging battery. Refer to the instructions
supplied with charging equipment
NOTE: The battery cannot be refilled with water, it
must be replaced.
A battery is considered fully charged when it will
meet all the following requirements.
²It has an open circuit voltage charge of at least
12.4 volts.
²It passes the 15 second load test, refer to the
Load Test Temperature chart.
²The built in test indicator dot is GREEN (Fig.
1).
Battery electrolyte will bubble inside of battery
case while being charged properly. If the electrolyte
boils violently, or is discharged from the vent holes
while charging, immediately reduce charging rate or
turn off charger. Evaluate battery condition. Battery
damage may occur if charging is excessive.
Some battery chargers are equipped with polarity
sensing devices to protect the charger or battery from
being damaged if improperly connected. If the bat-
tery state of charge is too low for the polarity sensor
to detect, the sensor must be bypassed for charger to
operate. Refer to operating instructions provided
with battery charger being used.
CAUTION: Charge battery until test indicator
appears green. Do not overcharge.
It may be necessary to jiggle the battery or vehicle
to bring the green dot in the test indicator into view.
Fig. 9 Testing Open Circuit Voltage
BATTERY OPEN CIRCUIT VOLTAGE
Open Circuit VoltsCharge Per-
centage
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
12.4 volts 75%
12.6 volts or more 100%
8A - 6 BATTERYNS
DIAGNOSIS AND TESTING (Continued)

(6) If battery passes load test, it is in good condi-
tion and further tests are not necessary. If it fails
load test, it should be replaced.
BATTERY OPEN CIRCUIT VOLTAGE TEST
An open circuit voltage no load test shows the
state of charge of a battery and whether it is ready
for a load test at 50 percent of the battery's cold
crank rating. Refer to Battery Load Test. If a battery
has open circuit voltage reading of 12.4 volts or
greater, and will not pass the load test, replace the
battery because it is defective. To test open circuit
voltage, perform the following operation.
(1) Remove both battery cables, negative cable
first. Battery top, cables and posts should be clean. If
green dot is not visible in indicator, charge the bat-
tery. Refer to Battery Charging Procedures.
(2) Connect a Volt/Ammeter/Load tester to the bat-
tery posts (Fig. 6). Rotate the load control knob of the
Carbon pile rheostat to apply a 300 amp load. Apply
this load for 15 seconds to remove the surface charge
from the battery, and return the control knob to off
(Fig. 7).(3) Allow the battery to stabilize for 2 minutes,
and then verify the open circuit voltage (Fig. 9).
(4) This voltage reading will approximate the state
of charge of the battery. It will not reveal battery
cranking capacity (Fig. 10).
SERVICE PROCEDURES
BATTERY CHARGING
WARNING: DO NOT CHARGE A BATTERY THAT
HAS EXCESSIVELY LOW ELECTROLYTE LEVEL.
BATTERY MAY SPARK INTERNALLY AND
EXPLODE. EXPLOSIVE GASES FORM OVER THE
BATTERY. DO NOT SMOKE, USE FLAME, OR CRE-
ATE SPARKS NEAR BATTERY. DO NOT ASSIST
BOOST OR CHARGE A FROZEN BATTERY. BAT-
TERY CASING MAY FRACTURE. BATTERY ACID IS
POISON, AND MAY CAUSE SEVERE BURNS. BAT-
TERIES CONTAIN SULFURIC ACID. AVOID CON-
TACT WITH SKIN, EYES, OR CLOTHING. IN THE
EVENT OF CONTACT, FLUSH WITH WATER AND
CALL PHYSICIAN IMMEDIATELY. KEEP OUT OF
REACH OF CHILDREN.
Fig. 8 Load 50% Cold Crank Rating
Load Test Temperature
Minimum VoltageTemperature
ÉF ÉC
9.6 volts 70É and
above21É and
above
9.5 volts 60É 16É
9.4 volts 50É 10É
9.3 volts 40É 4É
9.1 volts 30É -1É
8.9 volts 20É -7É
8.7 volts 10É -12É
8.5 volts 0É -18É
Fig. 9 Testing Open Circuit Voltage
Fig. 10 Battery Open Circuit Voltage
8A - 6 BATTERYNS/GS
DIAGNOSIS AND TESTING (Continued)

made to seal the area between the bedplate and cyl-
inder block without disturbing the bearing clearance
or alignment of these components.
GASKET DISASSEMBLY
Parts assembled with form-in-place gaskets may be
disassembled without unusual effort. In some
instances, it may be necessary to lightly tap the part
with a mallet or other suitable tool to break the seal
between the mating surfaces. A flat gasket scraper
may also be lightly tapped into the joint but care
must be taken not to damage the mating surfaces.
SURFACE PREPARATION
Scrape clean or wire brush all gasket surfaces to
remove all loose material. Inspect stamped parts to
ensure gasket rails are flat. Gasket surfaces must be
free of oil and dirt. Make sure old gasket material is
removed from blind attaching holes.
FORM-IN-PLACE GASKET APPLICATION
Assembling parts using a form-in-place gasket
requires care but it's easier then using precut gas-
kets.
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing the material off location.
TheMopartSilicone Rubber Adhesive Sealant
gasket material or equivalent should be applied in a
continuous bead approximately 3 mm (0.120 in.) in
diameter. All mounting holes must be circled. For
corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop
is placed in the center of the gasket contact area.
Uncured sealant may be removed with a shop towels.
Components should be torqued in place while the
sealant is still wet to the touch (within 10 minutes).
The usage of a locating dowel is recommended during
assembly to prevent smearing of material off loca-
tion.
CRANKSHAFT SPROCKET BOLT ACCESS PLUG
An Access plug is located in the right inner fender
shield. Remove the plug and insert the proper size
socket, extension and ratchet, when crankshaft rota-
tion is necessary.
ENGINE CORE PLUGS
REMOVAL
Using a blunt tool such as a drift or a screwdriver
and a hammer, strike the bottom edge of the cup
plug (Fig. 1). With the cup plug rotated, grasp firmlywith pliers or other suitable tool and remove plug
(Fig. 1).
CAUTION: Do not drive cup plug into the casting
as restricted cooling can result and cause serious
engine problems.
INSTALLATION
Thoroughly remove all rust and clean inside of cup
plug hole in cylinder block or head. Be sure to
remove old sealer. Lightly coat inside of cup plug hole
with sealer. Make certain the new plug is cleaned of
all oil or grease. Using proper drive plug, drive plug
into hole so that the sharp edge of the plug is at
least 0.5 mm (0.020 inch.) inside the lead in chamfer
(Fig. 1).
It is in not necessary to wait for curing of the seal-
ant. The cooling system can be refilled and the vehi-
cle placed in service immediately.
ENGINE PERFORMANCE
If a loss of performance is noticed, timing belt or
chain may have skipped one or two teeth. Camshaft
and crankshaft timing should be checked. Refer to
Group 9, Engine Timing belt or chain installation.
It is important that the vehicle is operating to its
optimum performance level to maintain fuel economy
and lowest vehicle emissions. If vehicle is not operat-
ing to these standards, refer to Engine Diagnosis out-
lined is this section. The following procedures can
assist in achieving the proper engine diagnosis.
(1) Test cranking amperage draw. Refer to Group
8B, Starting.
(2) Check intake manifold for vacuum leaks.
(3) Perform cylinder compression pressure test.
Refer to Engine Diagnosis, outlined in this section.
(4) Clean or replace spark plugs as necessary and
adjust gap as specified in Group 8D, Ignition System.
Tighten to specifications.
Fig. 1 Core Hole Plug Removal
9 - 2 ENGINENS
GENERAL INFORMATION (Continued)

components now have input (rationality) and output
(functionality) checks. Previously, a component like
the Throttle Position sensor (TPS) was checked by
the PCM for an open or shorted circuit. If one of
these conditions occurred, a DTC was set. Now there
is a check to ensure that the component is working.
This is done by watching for a TPS indication of a
greater or lesser throttle opening than MAP and
engine rpm indicate. In the case of the TPS, if engine
vacuum is high and engine rpm is 1600 or greater
and the TPS indicates a large throttle opening, a
DTC will be set. The same applies to low vacuum
and 1600 rpm.
Any component that has an associated limp in will
set a fault after 1 trip with the malfunction present.
Refer to the Diagnostic Trouble Codes Description
Charts in this section and the appropriate Power-
train Diagnostic Procedure Manual for diagnostic
procedures.
NON-MONITORED CIRCUITS
The PCM does not monitor all circuits, systems
and conditions that could have malfunctions causing
driveability problems. However, problems with these
systems may cause the PCM to store diagnostic trou-
ble codes for other systems or components. For exam-
ple, a fuel pressure problem will not register a fault
directly, but could cause a rich/lean condition or mis-
fire. This could cause the PCM to store an oxygen
sensor or misfire diagnostic trouble code.
The major non-monitored circuits are listed below
along with examples of failures modes that do not
directly cause the PCM to set a DTC, but for a sys-
tem that is monitored.
FUEL PRESSURE
The fuel pressure regulator controls fuel system
pressure. The PCM cannot detect a clogged fuel
pump inlet filter, clogged in-line fuel filter, or a
pinched fuel supply or return line. However, these
could result in a rich or lean condition causing the
PCM to store an oxygen sensor or fuel system diag-
nostic trouble code.
SECONDARY IGNITION CIRCUIT
The PCM cannot detect an inoperative ignition coil,
fouled or worn spark plugs, ignition cross firing, or
open spark plug cables.
CYLINDER COMPRESSION
The PCM cannot detect uneven, low, or high engine
cylinder compression.
EXHAUST SYSTEM
The PCM cannot detect a plugged, restricted or
leaking exhaust system. It may set a EGR or Fuel
system fault or O2S.
FUEL INJECTOR MECHANICAL
MALFUNCTIONS
The PCM cannot determine if a fuel injector is
clogged, the needle is sticking or if the wrong injector
is installed. However, these could result in a rich or
lean condition causing the PCM to store a diagnostic
trouble code for either misfire, an oxygen sensor, or
the fuel system.
EXCESSIVE OIL CONSUMPTION
Although the PCM monitors engine exhaust oxygen
content when the system is in closed loop, it cannot
determine excessive oil consumption.
THROTTLE BODY AIR FLOW
The PCM cannot detect a clogged or restricted air
cleaner inlet or filter element.
VACUUM ASSIST
The PCM cannot detect leaks or restrictions in the
vacuum circuits of vacuum assisted engine control
system devices. However, these could cause the PCM
to store a MAP sensor diagnostic trouble code and
cause a high idle condition.
PCM SYSTEM GROUND
The PCM cannot determine a poor system ground.
However, one or more diagnostic trouble codes may
be generated as a result of this condition. The mod-
ule should be mounted to the body at all times, also
during diagnostic.
PCM CONNECTOR ENGAGEMENT
The PCM may not be able to determine spread or
damaged connector pins. However, it might store
diagnostic trouble codes as a result of spread connec-
tor pins.
HIGH AND LOW LIMITS
The PCM compares input signal voltages from each
input device with established high and low limits for
the device. If the input voltage is not within limits
and other criteria are met, the PCM stores a diagnos-
tic trouble code in memory. Other diagnostic trouble
code criteria might include engine RPM limits or
input voltages from other sensors or switches that
must be present before verifying a diagnostic trouble
code condition.
NSEMISSION CONTROL SYSTEMS 25 - 11
DESCRIPTION AND OPERATION (Continued)