2001 DODGE TOWN AND COUNTRY engine coolant

²Check thePCV valveand replace if necessary.
Not required if previously changed.*
²Replace thespark plugson 2.4 liter engines.
²Inspect the generator belt on 2.4 liter engines
and replace if necessary.
²Inspect the serpentine drive belt (3.3 liter and
3.8 liter engines) and replace if necessary. This main-
tenance is not required if belt was previously
replaced.
²Change the All Wheel Drive (AWD) power trans-
fer unit fluid. (See the note at the end of Schedule ±
B.)
²Inspect the tie rod ends and boot seals.
²Inspect the brake linings.
93,000 Miles (149 000 km)
²Change the engine oil.
²Replace the engine oil filter.
96,000 Miles (154 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Drain and replace the automatic transmission
fluid and filter.
²Adjust bands on 3±speed transmission. (See the
note at the end of Schedule ± B.)
99,000 Miles (158 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the brake linings.
100,000 Miles (160 000 km)
²Flush and replace engine coolant at 60 months
or 100,000 miles (160 000 km).
102,000 Miles (163 000 km)
²Change the engine oil.
²Replace the engine oil filter.
105,000 Miles (168 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect theengine air cleaner element (fil-
ter)and replace as necessary.*
²Inspect the generator belt on 2.4 liter engines
and replace if necessary.
²Inspect the serpentine drive belt on 3.3 liter and
3.8 liter engines and replace if necessary. This main-
tenance is not required if the belt was previously
replaced.
²Change the All Wheel Drive (AWD) power trans-
fer unit fluid. (See the note at the end of Schedule ±
B.)
²Change the All Wheel Drive (AWD) overrunning
clutch and rear carrier fluid. (See the note at the end
of Schedule ± B.)
108,000 Miles (173 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the brake linings.
111,000 Miles (178 000 km)
²Change the engine oil.
²Replace the engine oil filter.
114,000 Miles (182 000 km)
²Change the engine oil.
²Replace the engine oil filter.
117,000 Miles (187 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the brake linings.
120,000 Miles (192 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Replace theengine air cleaner element (fil-
ter).
²Inspect thePCV valveand replace as neces-
sary.*
²Replace thespark plugson 2.4 liter engines.
²Inspect the generator belt and power steering
pump belt tension, replace the belt if necessary on
2.4 liter engines.
²Inspect the serpentine drive belt on 3.3 liter and
3.8 liter engines. Not required if replaced at 75,000,
90,000 or 105,000 miles.
²Replace theengine timing belton 2.4 liter
engines.
²Change the All Wheel Drive (AWD) power trans-
fer unit fluid. (See the note at the end of Schedule ±
B.)
²Inspect the tie rod ends and boot seals.
* This maintenance is recommended by Daimler-
Chrysler Corporation to the owner but is not
required to maintain the emissions warranty.
NOTE: Operating the vehicle more than 50% in
heavy traffic during hot weather, above 90ÉF (32ÉC),
using vehicle for police, taxi, limousine type opera-
tion or trailer towing require the more frequent tran-
saxle service noted in Schedule ± B. Perform these
services if vehicle usually operate under these con-
ditions.
NOTE: The AWD power transfer unit fluid and the
AWD overrunning clutch/rear carrier fluid must be
changed at the more frequent intervals shown in
schedule B if the vehicle is operated under any of
the conditions noted by an asterisk at the begin-
ning of the schedule.
RSLUBRICATION & MAINTENANCE0-15
MAINTENANCE SCHEDULES (Continued)
ProCarManuals.com

LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 4) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter
ªGº. Chassis lubricant is identified by the latter ªLº.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
SPECIALIZED LUBRICANTS AND OILS
Some maintenance or repair procedures may
require the use of specialized lubricants or oils. Con-
sult the appropriate sections in this manual for the
correct application of these lubricants.
DESCRIPTION - ENGINE COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less boiling protection.The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves and
engine block. Then coolant carries the heat to the
radiator where the tube/fin radiator can transfer the
heat to the air.
The use of aluminum cylinder blocks, cylinder
heads, and water pumps requires special corrosion
protection. MopartAntifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769), or the equiva-
lent ethylene glycol base coolant with hybrid organic
corrosion inhibitors (called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% Ethylene Glycol and 50% distilled
water to obtain a freeze point of -37ÉC (-35ÉF). If it
loses color or becomes contaminated, drain, flush,
and replace with fresh properly mixed coolant solu-
tion.
The green coolantMUST NOT BE MIXEDwith
the orange or magenta coolants. When replacing cool-
ant the complete system flush must be performed
before using the replacement coolant.
CAUTION: MoparTAntifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Doing so
will reduce the corrosion protection and may result
in premature water pump seal failure. If non-HOAT
coolant is introduced into the cooling system in an
emergency, it should be replaced with the specified
coolant as soon as possible.DESCRIPTION - AUTOMATIC TRANSMISSION
FLUID
NOTE: Refer to the maintenance schedules for the
recommended maintenance (fluid/filter change)
intervals for this transaxle.
NOTE: For fluid level checking procedures, (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH/FLUID - STANDARD PROCEDURE).
NOTE: The 31TH transaxle has a common transmis-
sion and differential sump. Filling the transaxle
accommodates the differential as well.
TRANSMISSION FLUID
MopartATF+4 (Automatic Transmission Fluid-
Type 9602) is required in this transaxle. Substitute
fluids can induce torque converter clutch shudder.
Fig. 4 NLGI Symbol
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
RGLUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESEL0a-3
FLUID TYPES (Continued)
ProCarManuals.com

FLUID FILL/CHECK
LOCATIONS
DESCRIPTION
The fluid check/fill points and lubrication locations
are located in each applicable service manual section.
MAINTENANCE SCHEDULES
MAINTENANCE SCHEDULES - DIESEL ENGINE
There are two maintenance schedules that show
proper service for the vehicle.
First is ScheduleªAº. It lists all the scheduled
maintenance to be performed under ªnormalº operat-
ing conditions.
Second is ScheduleªBº. It is a schedule for vehi-
cles that are operated under the conditions listed at
the beginning of the schedule.
Use the schedule that best describes the driving
conditions.
Where time and mileage are listed, follow the
interval that occurs first.
At Each Stop for Fuel
²Check the engine oil level, add as required.
²Check the windshield washer solvent and add if
required.
Once a Month
²Check the tire pressure and look for unusual
wear or damage.
²Inspect the battery and clean and tighten termi-
nals as required.
²Check the fluid levels of coolant reservoir, brake
master cylinder, power steering and transaxle and
add as needed.
²Check all lights and all other electrical items for
correct operation.
²Check the rubber seals on each side of the radi-
ator for proper fit.
At Each Oil Change
²Replace the engine oil filter at each oil change.
²Inspect exhaust system.
²Inspect brake hoses
²Inspect the CV joints and front suspension com-
ponents
²Rotate the tires at each oil change interval
shown on schedule ªAº 20 000 km or every other
interval shown on schedule ªBº 20 000 km.
²Check the coolant level, hoses, and clamps.
²Inspect brake linings, hoses and calipers.
²Inspect engine accessory drive belts.
²Inspect for presence of water in fuel filter/water
separator, drain if necessary.
SCHEDULE ªAº
20 000 km (12 000 miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Inspect air filter element. Replace as necessary.
40 000 km (24 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Replace air filter element.
²Replace fuel filter/water separator element. (2)
²Check alignment.
60 000 km (37 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Inspect air filter element. Replace as necessary.
80 000 km (49 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Replace air filter element.
²Replace fuel filter/water separator element. (2)
²Check alignment.
100 000 km (62 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Inspect air filter element. Replace as necessary.
120 000 km (75 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Replace air filter element.
²Replace fuel filter/water separator element. (2)
²Check alignment.
140 000 km (86 000 miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Inspect air filter element. Replace as necessary.
Fig. 6 Engine Oil Viscosity Recommendation ±
Diesel Engines
RGLUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESEL0a-5
FLUID TYPES (Continued)
ProCarManuals.com

160 000 km (100 000 miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Replace air filter element.
²Replace fuel filter/water separator element. (2)
²Check alignment.
²Flush and replace engine coolant. (3)
180 000 km (110 000 miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Inspect air filter element. Replace as necessary.
IMPORTANT: Inspection and service should also
be performed any time a malfunction is observed or
suspected. Retain all receipts.
²Change oil every 12 months regardless of mile-
age.
²The fuel filter/water separator element should
be replaced once a year if the vehicle is driven less
than 40 000 km annually or if power loss from fuel
starvation is detected.
²
Flush and replace engine coolant every 60 months
even if the vehicle is driven less than 160 000 km.
SCHEDULE ªBº
Follow this schedule if the vehicle is operated
under one or more of the following conditions.
²Day or night temperatures are below 0É C
(32É F).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 16.2 km (10 miles).
²More than 50% of driving is at sustained high
speeds during hot weather, above 32É C (90É F).
²Trailer towing.
²Taxi, police, or delivery service (commercial ser-
vice).
10 000 km (6 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Inspect air filter element.
20 000 km (12 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Replace air filter element.
²Replace fuel filter/water separator element. (2)
²Check alignment.
30 000 km (18 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Inspect air filter element.
40 000 km (24 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Replace air filter element.
²Replace fuel filter/water separator element. (2)
²Check alignment.
²Change manual transaxle fluid.
50 000 km (31 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Inspect air filter element.
60 000 km (37 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Replace air filter element.
²Replace fuel filter/water separator element. (2)
²Check alignment.
70 000 km (43 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Inspect air filter element.
80 000 km (49 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Replace air filter element.
²Replace fuel filter/water separator element. (2)
²Check alignment.
²Change manual transaxle fluid.
90 000 km (55 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Inspect air filter element.
100 000 km (62 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Replace air filter element.
²Replace fuel filter/water separator element. (2)
110 000 km (68 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Inspect air filter element.
²Replace fuel filter/water separator element. (2)
²Check alignment.
120 000 km (74 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Replace air filter element.
²Change manual transaxle fluid.
130 000 km (80 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
0a - 6 LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESELRG
MAINTENANCE SCHEDULES (Continued)
ProCarManuals.com

²Inspect air filter element.
²Replace fuel filter/water separator element. (2)
²Check alignment.
140 000 km (86 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Replace air filter element.
150 000 km (93 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Inspect air filter element.
²Replace fuel filter/water separator element. (2)
²Check alignment.
160 000 km (100 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Replace air filter element.
²Flush and replace engine coolant. (3)
²Change oil every 12 months regardless of mile-
age.
²The fuel filter/water separator element should
be replaced once a year if the vehicle is driven less
than 20 000 km annually or if power loss from fuel
starvation is detected.
²
Flush and replace engine coolant every 60 months
even if the vehicle is driven less than 160 000 km.
²Change manual transaxle fluid.
HOISTING
STANDARD PROCEDURE - HOISTING
Refer to Owner's Manual provided with vehicle for
proper emergency jacking procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN THE ENGINE OR REAR SUSPENSION
IS REMOVED FROM A VEHICLE, THE CENTER OF
GRAVITY IS ALTERED MAKING SOME HOISTING
CONDITIONS UNSTABLE. PROPERLY SUPPORT OR
SECURE VEHICLE TO HOISTING DEVICE WHEN
THESE CONDITIONS EXIST.
CAUTION: Do not position hoisting device on any
suspension component, including the front suspen-
sion crossmember, the rear leaf springs, and the
rear axle. Do not hoist on the front and rear
bumpers, the lower liftgate crossmember, the lower
radiator crossmember, the down standing flanges
on the sill or the front engine mount.
FOR PROPER HOIST PLACEMENT REFER
TO (Fig. 7).The hoisting points are identified by S.A.E.
inverted triangle hoisting symbols (Fig. 7). The front
hoisting points are at the bottom of the font rail
below the hoisting symbol approximately 250mm
behind the front suspension crossmember. When
using outboard lift hoists, verify that the hoist lift
pads have been properly adjusted to eliminate con-
tact between the hoist arm and the down standing
flange on the sill. The rear hoisting points are the
leaf spring front mounting brackets. The hoist pad
must be positioned to pick up the flanges on the
bracket, not the leaf spring.
When servicing the leaf springs or the leaf spring
mounting brackets, special provisions are required to
support the rear of the vehicle. Position the rear
hoist pads under the horizontal surface on the bot-
tom of the sill, inboard adjacent to the flange and
centered fore/aft between the jacking indicator tabs
on the lower flange.DO NOT HOIST ON THE
FLANGE.Place a soft pad between the hoist and the
painted surface on the sill to avoid scratching the fin-
ish.
Fig. 7 HOISTING AND JACKING POINTS
1 - Drive On Lift
2 - Frame Contact Lift (Single Post)
Chassis Lift (Non-Axle Dual Post)
Outboard Lift (Dual Post)
Floor Jack
3 - S.A.E. Hoisting Symbols
RGLUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESEL0a-7
MAINTENANCE SCHEDULES (Continued)
ProCarManuals.com

STANDARD PROCEDURE - BRAKE FLUID
LEVEL CHECKING
Check master cylinder reservoir fluid level a mini-
mum of twice annually.
Fluid reservoirs are marked with the words FULL
and ADD to indicate proper brake fluid fill level of
the master cylinder.
If necessary, add brake fluid to bring the level to
the bottom of the FULL mark on the side of the mas-
ter cylinder fluid reservoir.
Use only Mopartbrake fluid or equivalent from a
sealed container. Brake fluid must conform to DOT 3
specifications (DOT 4 or DOT 4+ are acceptable).
DO NOTuse brake fluid with a lower boiling
point, as brake failure could result during prolonged
hard braking.
Use only brake fluid that was stored in a tightly-
sealed container.
DO NOTuse petroleum-based fluid because seal
damage will result. Petroleum based fluids would be
items such as engine oil, transmission fluid, power
steering fluid etc.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications (DOT 4 and DOT 4+ are
acceptable) and SAE J1703 standards. No other type
of brake fluid is recommended or approved for usage
in the vehicle brake system. Use only MopartBrake
Fluid or equivalent from a tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container of brake fluid will absorb moisture
from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would
be items such as engine oil, transmission fluid,
power steering fluid, etc.
JUNCTION BLOCK
DESCRIPTION - NON-ABS JUNCTION BLOCK
A junction block is used on vehicles that are not
equipped with antilock brakes (ABS). The junction
block mounts in the same location as the integrated
control unit (ICU) does on vehicles equipped withABS. This allows for use of the same brake tube con-
figuration on all vehicles. The junction block is
located on the driver's side of the front suspension
cradle/crossmember below the master cylinder (Fig.
46).
It has six threaded ports to which the brake tubes
connect. Two are for the primary and secondary
brake tubes coming from the master cylinder. The
remaining four are for the chassis brake tubes going
to each brake assembly.
OPERATION - NON-ABS JUNCTION BLOCK
The junction block distributes the brake fluid com-
ing from the master cylinder primary and secondary
ports to the four chassis brake tubes leading to the
brakes at each wheel. Since the junction block
mounts in the same location as the ABS integrated
control unit (ICU), it allows for the common use of
brake tubes going to the brakes whether the vehicle
is equipped with or without ABS.
NOTE: Although the brake tubes coming from the
master cylinder to the junction block or ABS ICU
may appear to be the same, they are not. They are
unique to each brake system application.
REMOVAL - NON-ABS JUNCTION BLOCK
(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) Disconnect the battery negative cable.
(3) If the vehicle is equipped with speed control,
perform the following:
(a) Disconnect the battery positive cable.
(b) Remove the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - REMOVAL).
(c) Disconnect the vacuum hose connector at the
tank built into the battery tray.
(d) Remove the screw securing the coolant filler
neck to the battery tray.
(e) Remove the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - REMOVAL).
(f) Remove the fasteners and move the speed
control servo off to the side, out of the way.
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
hydraulic system.
5 - 32 BRAKES - BASERS
FLUID (Continued)
ProCarManuals.com

(4) Remove the four chassis brake tubes from the
top of the junction block (Fig. 46).
(5) Remove the primary and secondary brake
tubes from the top of the junction block.
(6) Remove the bolts attaching the junction block
mounting bracket to the front suspension crossmem-
ber (Fig. 46), then remove the junction block.
INSTALLATION - NON-ABS JUNCTION BLOCK
(1) Install the junction block and mounting bracket
on the front suspension crossmember (Fig. 46).
Install the mounting bolts and tighten to a torque of
28 N´m (250 in. lbs.).
(2) Install the primary and secondary brake tubes
from the master cylinder in their ports. Tighten tube
nuts to a torque of 17 N´m (145 in. lbs.).Take care
not to twist tubes when tightening tube nuts.
They must be properly positioned to allow free
movement with rubber isolated suspension
crossmember.
(3) Install the four chassis brake tubes into the
outlet ports of the junction block. Tighten all 6 tube
nuts to a torque of 17 N´m (145 in. lbs.).
(4) If the vehicle is equipped with speed control,
perform the following:
(a) Install the speed control servo with its
mounting nuts.
(b) Connect the wiring harness to the speed con-
trol servo.
(c) Install the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - INSTALLA-
TION).(d) Install the screw securing the coolant filler
neck to the battery tray.
(e) Reconnect the vacuum hose connector at the
tank built into the battery tray.
(f) Install the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION).
(g) Install the battery shield.
(5) Remove the brake pedal holder.
(6) Connect negative cable back on negative post of
the battery.
(7) Bleed the brake system thoroughly to ensure
that all air has been expelled from the hydraulic sys-
tem. (Refer to 5 - BRAKES - STANDARD PROCE-
DURE).
(8) Road test the vehicle to verify proper operation
of the brake system.
MASTER CYLINDER
DESCRIPTION
The master cylinder is located on the power brake
booster in the engine compartment on the driver's
side (Fig. 47). This vehicle uses 3 different master
cylinders. Master cylinder usage depends on what
type of brake system the vehicle is equipped with.
CAUTION: Master cylinders are not interchangeable
between systems. Performance and stopping dis-
tance issues will result if the incorrect master cyl-
inder is installed on the vehicle.
Fig. 46 NON-ABS JUNCTION BLOCK
1 - MASTER CYLINDER
2 - JUNCTION BLOCK
3 - SUSPENSION CROSSMEMBER
4 - MOUNTING BOLTS
Fig. 47 MASTER CYLINDER AND BOOSTER
LOCATION
1 - MASTER CYLINDER
2 - POWER BRAKE BOOSTER
RSBRAKES - BASE5-33
JUNCTION BLOCK (Continued)
ProCarManuals.com

DIAGNOSIS AND TESTING - POWER BRAKE
BOOSTER
BASIC TEST
(1) With engine off, depress and release the brake
pedal several times to purge all vacuum from the
power brake booster.
(2) Depress and hold the pedal with light effort (15
to 25 lbs. pressure), then start the engine.
The pedal should fall slightly, then hold. Less effort
should be needed to apply the pedal at this time. If
the pedal fell as indicated, perform the VACUUM
LEAK TEST listed after the BASIC TEST. If the
pedal did not fall, continue on with this BASIC TEST.
(3) Disconnect the vacuum hose on the vacuum
check valve, then place a vacuum gauge in line
between the vacuum hose and the valve.
(4) Start the engine.
(5) When the engine is at warm operating temper-
ature, allow it to idle and check the vacuum at the
gauge.
If the vacuum supply is 12 inches Hg (40.5 kPa) or
more, the power brake booster is defective and must
be replaced. If the vacuum supply is below 12 inches
Hg, continue on with this BASIC TEST.
(6) Shut off the engine.
(7) Connect the vacuum gauge to the vacuum ref-
erence port on the engine intake manifold.
(8) Start the engine and observe the vacuum
gauge.
If the vacuum is still low, check the engine tune
and repair as necessary. If the vacuum is above 12
inches Hg, the hose or check valve to the booster has
a restriction or leak.
Once an adequate vacuum supply is obtained,
repeat the BASIC TEST.
VACUUM LEAK TEST
(1) Disconnect the vacuum hose on the vacuum
check valve, then place a vacuum gauge in line
between the vacuum hose and the valve.
(2) Start the engine.
(3) Allow the engine to warm up to normal operat-
ing temperature and engine idle.
(4) Using vacuum line pliers, close off the vacuum
supply hose near the booster, but before the vacuum
gauge, then observe the vacuum gauge.
If the vacuum drop exceeds 1.0 inch Hg (3.3 kPa)
in one minute, repeat the above steps to confirm the
reading. The vacuum loss should be less than 1.0
inch Hg in one minute time span. If the loss is more
than 1.0 inch Hg, replace the power brake booster. If
it is not, continue on with this test.
(5) Remove the pliers from the hose temporarily.
(6) Apply light effort (approximately 15 lbs. of
force) to the brake pedal and hold the pedal steady.Do not move the pedal once the pressure is applied
or the test results may vary.
(7) Have an assistant reattach the vacuum line
pliers to the vacuum supply hose.
(8) Allow 5 seconds for stabilization, then observe
the vacuum gauge.
If the vacuum drop exceeds 3.0 inches Hg (10 kPa)
in 15 seconds, repeat the above steps to confirm the
reading. The vacuum loss should be less than 3.0
inches Hg in 15 seconds time span. If the loss is
more than 3.0 inches Hg, replace the power brake
booster. If it is not, the booster is not defective.
(9) Remove the pliers and vacuum gauge.
REMOVAL - POWER BRAKE BOOSTER
CAUTION: Reserve vacuum in power brake booster
must be pumped down (removed) before removing
master cylinder from booster. This is necessary to
prevent booster from sucking in any contamination
as master cylinder is removed. This can be done
simply by pumping the brake pedal, with the vehi-
cle'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 negative battery cable terminal from
battery.
(3) Remove positive battery cable terminal from
battery.
(4) Remove battery thermal guard shield.
(5) Remove battery clamp, nut and battery from
the battery tray.
(6) Remove screw securing engine coolant filler
tube to battery tray.
(7) If the vehicle is equipped with speed control,
disconnect the vacuum hose at the vacuum tank built
into the battery tray.
(8) Remove the two nuts and one bolt securing bat-
tery tray in place. Remove battery tray.
(9) If vehicle is equipped with speed control:
(a) Disconnect wiring harness connector from
the speed control servo.
(b) Remove the two servo mounting nuts.
(c) Lay speed control servo off to the side, out of
the way.
(10) Remove the wiper module (unit). (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - REMOVAL)
(11) Disconnect wiring harness connector from
brake fluid level switch in master cylinder fluid res-
ervoir (Fig. 54).
5 - 38 BRAKES - BASERS
POWER BRAKE BOOSTER (Continued)
ProCarManuals.com