2002 CHRYSLER CARAVAN ECU

SUPPORT PLATE - DRUM
BRAKE
REMOVAL
(1) Using a brake pedal depressor, move and
secure brake pedal to a position past its first 1 inch
of travel. This will prevent brake fluid from draining
out of master cylinder when brake tube is remove
from wheel cylinder.
(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(3) Remove wheel and tire assembly.
(4) Disconnect brake tube from rear of wheel cylin-
der. Cap open ends
(5) Remove brake drum.
(6) Remove brake shoes from brake support plate.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
BRAKE PADS/SHOES - REMOVAL).
(7) Remove the 2 bolts attaching the wheel cylin-
der to the brake support plate.
(8) Remove the wheel cylinder from the brake sup-
port plate.
(9) Disconnect the park brake cable from the park
brake actuation lever.
(10) Using a suitable tool such as a 14 mm box
wrench (Fig. 103) or an aircraft type hose clamp,
compress the flared legs on park brake cable
retainer. Then pull the park brake cable out of brake
support plate.(11) Remove the rear hub and bearing. (Refer to 2
- SUSPENSION/REAR/HUB / BEARING -
REMOVAL)
(12) Remove the rear brake support plate from the
rear axle.
INSTALLATION
(1) Install the 4 hub and bearing to axle mounting
bolts into the mounting holes in the flange of the
rear axle.
(2) Install the rear brake support plate on the 4
mounting bolts installed in the flange of the rear axle
(Fig. 104).
(3) Install the rear hub and bearing (and connect
wheel speed sensor where applicable) stopping short
of installing the brake drum. (Refer to 2 - SUSPEN-
SION/REAR/HUB / BEARING - INSTALLATION)
(4) Install the rear park brake cable into its
mounting hole in the rear brake support plate.
(5) Install the park brake cable on the park brake
actuation lever.
(6) Apply sealant such as Mopar Gasket-In-A-Tube
or equivalent around the wheel cylinder opening in
the brake support plate.
(7) Install wheel cylinder onto brake support.
Install and tighten the wheel cylinder to brake sup-
port plate attaching bolts to 8 N´m (75 in. lbs.)
torque.
(8) Install brake tube into wheel cylinder. Tighten
tube nut to a torque of 17 N´m (145 in. lbs.) torque.
(9) Install the rear brake shoes on the brake sup-
port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION).
(10) Install brake drum.
Fig. 103 Removing Park Brake Cable From Brake
Support Plate
1 - PARK BRAKE CABLE
2 - CABLE RETAINER
3 - 14 mm BOX WRENCH
4 - BRAKE SUPPORT PLATE
Fig. 104 Brake Support Plate Mounted On Bearing
Attaching Bolts
1 - REAR BRAKE SUPPORT PLATE
2 - HUB/BEARING MOUNTING BOLTS
5 - 64 BRAKES - BASERS
ProCarManuals.com

(11) Install wheel and tire.
(12) Tighten wheel stud nuts to 135 N´m (100 ft.
lbs.).
(13) Adjust drum brake shoes. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - ADJUSTMENTS)
(14) Remove brake pedal depressor tool.
(15) Bleed the brake system as necessary. (Refer to
5 - BRAKES - BASE - STANDARD PROCEDURE).
(16) Lower the vehicle.
WHEEL CYLINDERS
REMOVAL
(1) Using a brake pedal depressor, move and
secure brake pedal to a position past its first 1 inch
of travel. This will prevent brake fluid from draining
out of master cylinder when brake tube is remove
from wheel cylinder.
(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(3) Remove wheel and tire assembly.
(4) Disconnect brake tube from rear of wheel cylin-
der. Cap open ends
(5) Remove brake drum.
(6) Remove brake shoes from brake support plate
(Discard if contaminated).(Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/BRAKE PADS/SHOES -
REMOVAL)
(7) Remove the 2 bolts attaching the wheel cylin-
der to the brake support plate.
(8) Remove the wheel cylinder from the brake sup-
port plate.
INSPECTION
With brake drums removed, inspect the wheel cyl-
inder boots for evidence of a brake fluid leak. Visu-
ally check the boots for cuts, tears, or heat cracks. If
any of these conditions exist, the wheel cylinders
should be completely cleaned, inspected and new
parts installed.
If a wheel cylinder is leaking and the brake lining
material is saturated with brake fluid, the brake
shoes must be replaced.
INSTALLATION
(1) Apply sealant such as Mopar Gasket-In-A-Tube
or equivalent around the wheel cylinder opening in
the brake support plate.
(2) Install wheel cylinder onto brake support.
Install and tighten the wheel cylinder to brake sup-
port plate attaching bolts to 8 N´m (75 in. lbs.)
torque.(3) Install brake tube into wheel cylinder. Tighten
tube nut to a torque of 17 N´m (145 in. lbs.) torque.
(4) Install the rear brake shoes on the brake sup-
port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION).
(5) Install brake drum.
(6) Install wheel and tire. Install and tighten
wheel lug nuts to 135 N´m (100 ft. lbs.).
(7) Adjust drum brake shoes. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - ADJUSTMENTS)
(8) Remove brake pedal depressor tool.
(9) Bleed the brake system as necessary. (Refer to
5 - BRAKES - BASE - STANDARD PROCEDURE).
(10) Lower vehicle.
PARKING BRAKE
DESCRIPTION
DESCRIPTION
The parking brake system is operated by a foot
operated parking brake lever. The parking brake
lever is mounted on the body of the vehicle to the left
of the brake pedal (Fig. 105). It is a automatic-ad-
justing type lever.
Fig. 105 Parking Brake Lever (Pedal)
1 - PARK BRAKE PEDAL ASSEMBLY
2 - PARK BRAKE PEDAL
3 - CARPET
4 - FRONT PARK BRAKE CABLE
5 - SEAL
6 - FLOOR PAN
RSBRAKES - BASE5-65
SUPPORT PLATE - DRUM BRAKE (Continued)
ProCarManuals.com

(10) Remove cable retainer from the parking brake
lever (pedal) assembly bracket.
(11) Pull front parking brake cable assembly out of
vehicle through hole in floor pan.
REMOVAL - PARKING BRAKE CABLE
(INTERMEDIATE)
(1) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(2) Manually lock out the automatic self-adjusting
mechanism tension of the parking brake lever (pedal)
assembly. (Refer to 5 - BRAKES - STANDARD PRO-
CEDURE). Once the cable is released from the equal-
izer, do not remove the locking pliers until
reinstallation of the cable is complete.
(3) Remove the intermediate parking brake cable
from the parking brake cable equalizer (Fig. 111).
(4) Remove the locking nut securing the interme-
diate cable housing to the side bracket on the frame
rail (Fig. 111).
(5) Remove the intermediate parking brake cable
from the cable connector attaching it to the right
rear parking brake cable (Fig. 112). Remove the lock-
ing nut securing the intermediate cable housing to
the side bracket on the frame rail (Fig. 112).
(6) If the vehicle is a short-wheel-base model, it
will be necessary to loosen and lower the fuel tank
far enough to remove the intermediate parking brake
cable. (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY/FUEL TANK - REMOVAL).
(7) Remove the intermediate parking brake cable
from the side brackets and vehicle.
Fig. 109 Front Park Brake Cable Attachment To
Body
1 - CABLE HOUSING RETAINER
2 - BODY OUTRIGGER BRACKET
3 - PUSH WRENCH OVER END OF RETAINER HERE
4 - FRONT PARK BRAKE CABLE
Fig. 110 Front Park Brake Cable At Floor Pan
1 - PARK BRAKE PEDAL ASSEMBLY
2 - PARK BRAKE PEDAL
3 - CARPET
4 - FRONT PARK BRAKE CABLE
5 - SEAL
6 - FLOOR PAN
Fig. 111 Parking Brake Cable Attachment To
Equalizer
1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
5 - 68 BRAKES - BASERS
CABLES - PARKING BRAKE (Continued)
ProCarManuals.com

(7) Remove the brake shoes from the brake sup-
port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES - REMOVAL).
(8) Disconnect parking brake cable from parking
brake actuator lever.
(9) Remove the parking brake cable housing
retainer from the brake support plate using a 14mm
wrench to compress the retaining fingers (Fig. 120).
INSTALLATION
INSTALLATION - PARKING BRAKE CABLE
(FRONT)
(1) Pass front parking brake cable assembly
through hole in floor pan from the inside of the vehi-
cle.
(2) Pass cable strand button through the hole in
the lever (pedal) assembly bracket.
(3) Install cable retainer onto the park brake cable
and then install cable retainer into pedal assembly
bracket.
(4) Install the end of the park brake cable into the
retainer previously installed into the park brake
pedal bracket.
(5) Install cable strand button into the clevis on
the park brake pedal mechanism.
(6) Install the front park brake cable floor pan seal
into hole in floor pan. Seal is to be installed so the
flange on the seal is flush with the floor pan (Fig.
110). Fold carpeting back down on floor.
(7) Raise vehicle.
(8) Insert brake cable and housing into body out-
rigger bracket making certain that housing retainer
fingers lock the housing firmly into place (Fig. 109).
(9) Manually reset the automatic self-adjusting
mechanism tension of the parking brake lever (pedal)
assembly. (Refer to 5 - BRAKES - STANDARD PRO-
CEDURE).
(10) Assemble the park brake cables onto the park
brake cable equalizer (Fig. 108).
(11) Lower vehicle and apply the park brake pedal
1 time. This will seat the parking brake cables.
INSTALLATION - PARKING BRAKE CABLE
(INTERMEDIATE)
(1) Install the ends of the park brake cables
through the frame rails and into the side brackets.
(2) Install the locking nuts at each end of the cable
and securely tighten (Fig. 111) (Fig. 112).
(3) If the vehicle is a short-wheel-base model, it
will be necessary to reinstall the fuel tank to its nor-
mal mounting position. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL TANK -
INSTALLATION).
(4) Install the intermediate parking brake cable on
the cable connector at the right rear parking brake
cable (Fig. 112).
(5) Install the intermediate park brake cable on
the cable equalizer (Fig. 111).
(6) Remove the locking pliers from the front park
brake cable. This will activate the automatic adjuster
and correctly adjust the parking brake cables.
Fig. 119 Parking Brake Cable Removal From Body
Bracket
1 - LEFT REAR PARK BRAKE CABLE
2 - BODY BRACKET
3 - LEAF SPRING MOUNTING BRACKET
4 - CABLE RETAINER
5 - 14MM BOX WRENCH
Fig. 120 Removing Parking Brake Cable From Brake
Support Plate
1 - PARK BRAKE CABLE RETAINER
2 - PARK BRAKE CABLE
3 - 14MM BOX WRENCH
4 - BRAKE SUPPORT PLATE
RSBRAKES - BASE5-71
CABLES - PARKING BRAKE (Continued)
ProCarManuals.com

(12) Compress the parking brake cable retainer by
sliding a 14 mm wrench over the cable retainer and
compress the three (3) retaining fingers.
(13) Remove the three screws from the parking
brake grommet on the floor pan of the passenger
compartment.
(14) Lift the parking brake lever and slide the
parking brake cable out.
(15) Pull the cable through the floor pan from
inside the vehicle.
INSTALLATION - PARKING BRAKE LEVER AND
FRONT CABLE
(1) Pass the parking brake cable down through the
hole in the floor pan from inside of vehicle.
(2) Pass cable end button through the hole in the
lever bracket and press the cable housing into the
hole until all three retaining fingers lock the cable to
the lever bracket.
(3) Hook the end of the parking brake cable on the
parking brake lever mechanism.
(4) Press the cable grommet into the hole in the
floor pan and install the three screws securing it to
the floor pan.
(5) If equipped with a manual transaxle, install
the gearshift mechanism. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/SHIFT MECHANISM
- INSTALLATION)
(6) Install the floor console. (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - INSTALLATION)
(7) Raise the vehicle.
(8) Install the four mounting nuts securing the
parking brake lever bracket in place.
(9) Install the front park cable housing retainer to
the body outrigger bracket. Press the cable housing
into the outrigger hole until all three retaining fin-
gers lock the cable in place.
(10) Grasp the exposed section of the front parking
brake cable and pull rearward on it. While holding
the park brake in this position, install a pair of lock-
ing pliers on the front parking brake cable just rear-
ward of the second body outrigger bracket.
(11) Install the equalizer on the front parking
brake cable and install the left rear and intermediate
park brake cable in the correct location on the park-
ing brake cable equalizer (Fig. 124).(12) Remove the locking pliers from the front park-
ing brake cable. This will allow the adjuster in the
park brake lever mechanism to tension the parking
brake cables.
(13) Lower the vehicle.
(14) Apply and release the parking brake lever one
time. This will seat the parking brake cables and
allow the auto adjuster in the parking brake lever
mechanism to correctly tension the parking brake
cables.
SHOES - PARKING BRAKE
REMOVAL
(1) AWD only - Set the parking brake.The park-
ing brake is set to keep the hub/bearing and
axle shaft from rotating when loosening the
hub nut.
(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(3) Remove the wheel and tire assembly.
(4) AWD only - Remove the cotter pin and nut
retainer (Fig. 125) from the stub shaft of the outer
C/V joint.
Fig. 125 Cotter Pin And Nut Retainer
1 - CALIPER
2 - COTTER PIN
3 - ROTOR
4 - NUT RETAINER
5 - OUTER C/V JOINT
RSBRAKES - BASE5-75
LEVER - PARKING BRAKE (EXPORT) (Continued)
ProCarManuals.com

(1) Connect the front wheel speed sensor cable to
the vehicle wiring harness connector. Be sure speed
sensor cable connector is fully seated and locked into
vehicle wiring harness connector.
(2) Install the bolts attaching the routing clamps
to the body of the vehicle. Tighten the bolts to a
torque of 14 N´m (125 in. lbs.).
(3) Insert speed sensor cable grommets into inter-
mediate bracket on strut.
(4) Install the wheel speed sensor head mounting
bolt (Fig. 1). Tighten the bolt to a torque of 13 N´m
(115 in. lbs.)
(5) Install the wheel and tire assembly on vehicle.
(6) Lower vehicle.
(7) Road test vehicle to ensure proper operation of
the base and ABS brake systems.
REAR WHEEL SPEED SENSOR
-AWD
REMOVAL
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
CAUTION: When disconnecting 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.(2) Remove grommet from floor pan of vehicle and
disconnect speed sensor cable connector from vehicle
wiring harness.
CAUTION: When removing rear wheel speed sensor
cable from routing clips, be sure not to damage the
routing clips. Routing clips that are molded onto
the brake hose will require replacement of the brake
hose if damaged during removal or installation of
the speed sensor cable.
(3) Carefully remove speed sensor cable from
press-in routing clips along brake hose and tubing.
(4) Remove bolt securing wheel speed sensor cable
metal clip to rear of axle. Remove metal clip from
cable if necessary.
CAUTION: If speed sensor head has seized due to
corrosion, do not use pliers on speed sensor head
in an attempt to remove it. Use a hammer and a
punch and tap mounting flange edge side-to-side,
rocking the sensor until free.
(5) Remove wheel speed sensor head attaching
bolt.
(6) Remove wheel speed sensor head from the axle,
and remove sensor from vehicle.
INSTALLATION
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 indicated may
result in contact with moving parts or over-exten-
sion of cables, resulting in an open circuit.
(1) Install wheel speed sensor head in axle flange.
CAUTION: Prior to installing the speed sensor head
attaching bolt, the plastic anti-rotation pin must be
fully seated into the bearing flange.
(2) Install wheel speed sensor head attaching bolt.
Tighten bolt to a torque 10 N´m (90 in. lbs.).
(3) Check the air gap between the face of the
wheel speed sensor and the top surface of the tone
wheel. (Refer to 5 - BRAKES - SPECIFICATIONS)
CAUTION: When installing wheel speed sensor
cable in the 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 hose if damaged.
(4) Install speed sensor cable under leaf spring
onto brake hose and tubing utilizing routing clips to
secure it in place.
Fig. 1 Front Wheel Speed Sensor Attaching Bolt
1 - MOUNTING BOLT
2 - WHEEL SPEED SENSOR
3 - DRIVESHAFT
4 - TONE WHEEL
5 - STEERING KNUCKLE
5 - 90 BRAKES - ABSRS
FRONT WHEEL SPEED SENSOR (Continued)
ProCarManuals.com

(5) Install metal routing clip on speed sensor cable
and mount it to rear of axle with mounting bolt.
Tighten mounting bolt to 16 N´m (140 in. lbs.).
(6) Connect wheel speed sensor cable to vehicle
wiring harness.Be sure speed sensor cable con-
nector is fully seated and locked into vehicle
wiring harness connector.
(7) Install speed sensor cable grommet into the
floor pan, being sure the grommet is fully seated into
the access hole.
(8) Lower vehicle.
(9) Road test vehicle to ensure proper operation of
the base and ABS braking systems.
REAR WHEEL SPEED SENSOR
- FWD
REMOVAL
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
CAUTION: When disconnecting 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.
(2) Remove grommet from floor pan of vehicle and
disconnect speed sensor cable connector from vehicle
wiring harness (Fig. 2).
CAUTION: When removing rear wheel speed sensor
cable from routing clips, be sure not to damage the
routing clips. Routing clips that are molded ontothe brake hose will require replacement of the brake
hose if damaged during removal or installation of
the speed sensor cable.
(3) Carefully remove speed sensor cable from
press-in routing clips (Fig. 3).
(4) Remove bolt securing metal routing clip to rear
of axle and remove sensor cable from metal clip (Fig.
3).
(5) Remove secondary (yellow) retaining clip at
rear of wheel speed sensor head (Fig. 4).
(6) Push up on metal retaining clip (Fig. 4) until it
bottoms. This will release wheel speed sensor head
from hub and bearing. While holding metal clip up,
pull back on wheel speed sensor head removing it
from hub and bearing.
(7) Remove wheel speed sensor assembly from
vehicle.
INSTALLATION
CAUTION: Proper installation of wheel speed sen-
sor cable is critical to continued system operation.
Be sure that cable is installed in routing retainers/
clips. Failure to install cable in retainers may result
in contact with moving parts or over extension of
cable, resulting in an open circuit.
NOTE: Make sure wheel speed sensor stays clean
and dry as it is installed into the hub and bearing
cap.
(1) If metal sensor retaining clip is not in the neu-
tral installed position on hub and bearing cap, install
from the bottom, if necessary, and push clip upward
until it snaps into position.
Fig. 2 Wheel Speed Sensor Connector
1 - CONNECTOR
2 - FLOOR PAN
3 - GROMMET
Fig. 3 SPEED SENSOR CABLE ROUTING
1 - METAL CLIP AND MOUNTING BOLT
2 - ROUTING CLIPS
RSBRAKES - ABS5-91
REAR WHEEL SPEED SENSOR - AWD (Continued)
ProCarManuals.com

ICU (INTEGRATED CONTROL
UNIT)
DESCRIPTION
The hydraulic control unit (HCU) and the control-
ler antilock brake (CAB) used with this antilock
brake system are combined (integrated) into one
unit, which is called the integrated control unit (ICU)
(Fig. 12). The ICU is located below the master cylin-
der in the engine compartment (Fig. 13).Two different ICU's (HCU and CAB) are used on
this vehicle depending on whether or not the vehicle
is equipped with traction control. The HCU on a
vehicle equipped with traction control has a valve
block that is approximately one inch longer than a
HCU on a vehicle that is equipped with ABS only.
The ABS-only ICU consists of the following compo-
nents: the CAB, eight (build/decay) solenoid valves
(four inlet valves and four outlet valves), valve block,
fluid accumulators, a pump, and an electric motor.
The ABS-with traction control ICU consists of the
following components: the CAB, eight (build/decay)
solenoid valves (four inlet valves and four outlet
valves), two traction control (ASR) valves, two
hydraulic shuttle valves, valve block, fluid accumula-
tors, a pump, and an electric motor.
The replaceable components of the ICU are the
HCU and the CAB. No attempt should be made to
service any individual components of the HCU or
CAB. For information on the CAB, (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MOD-
ULES/CONTROLLER ANTILOCK BRAKE -
DESCRIPTION).
OPERATION
For information of the ICU, refer to these individ-
ual components of the ICU:
²CONTROLLER ANTILOCK BRAKE (CAB)
(Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/CONTROLLER ANTILOCK
BRAKE - OPERATION)
²HYDRAULIC CONTROL UNIT (HCU) (Refer to
5 - BRAKES - ABS/HYDRAULIC/MECHANICAL/
HCU (HYDRAULIC CONTROL UNIT) - OPERA-
TION)
For information on the ICU's hydraulic circuits,
refer to HYDRAULIC CIRCUITS AND VALVE
OPERATION. (Refer to 5 - BRAKES - ABS/HY-
DRAULIC/MECHANICAL - OPERATION)
REMOVAL
REMOVAL - LHD
(1) Disconnect the negative (ground) cable from
the battery and isolate cable.
(2) Remove the battery shield.
(3) Remove the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - REMOVAL).
(4) Disconnect the vacuum hose connector at the
tank built into the battery tray.
(5) Remove the screw securing the engine coolant
filler neck to the battery tray.
(6) Remove the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - REMOVAL).
Fig. 12 INTEGRATED CONTROL UNIT (ICU)
1 - PUMP/MOTOR
2 - HCU
3 - PUMP/MOTOR CONNECTOR
4 - CAB
Fig. 13 ICU LOCATION IN VEHICLE
1 - POWER BRAKE BOOSTER
2 - MASTER CYLINDER
3 - ICU
5 - 100 BRAKES - ABSRS
ProCarManuals.com