2003 CHRYSLER CARAVAN battery

CAUTION
CAUTIONS
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.
CAUTION: In testing for open or short circuits, do
not ground or apply voltage to any of the circuits
unless instructed to do so for a diagnostic proce-
dure.
CAUTION: These circuits should only be tested
using a high impedance multi-meter or the DRBIIIT
scan tool 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: The CAB 24-way connector should never
be connected or disconnected with the ignition
switch in the ON position.
CAUTION: This vehicle utilizes active wheel speed
sensors. Do not apply voltage to wheel speed sen-
sors at any time.
CAUTION: Use only factory wiring harnesses. Do
not cut or splice wiring to the brake circuits. The
addition of aftermarket electrical equipment (car
phone, radar detector, citizen band radio, trailer
lighting, trailer brakes, etc.) on a vehicle equipped
with antilock brakes may affect the function of the
antilock brake system.
CAUTION: When performing any service procedure
on a vehicle equipped with ABS, do not apply a
12-volt power source to the ground circuit of the
pump motor in the HCU. Doing this will damage the
pump motor and will require replacement of the
entire HCU.
CAUTION: An attempt to remove or disconnect cer-
tain system components may result in improper
system operation. Only those components with
approved removal and installation procedures in
this manual should be serviced.CAUTION: If welding work is to be performed on the
vehicle, using an electric arc welder, the CAB con-
nector should be disconnected during the welding
operation.
CAUTION: Many components of the ABS System
are not serviceable and must be replaced as an
assembly. Do not disassemble any component
which is not designed to be serviced.
CAUTION: Only the recommended jacking or hoist-
ing positions for this vehicle are to be used when-
ever it is necessary to lift a vehicle. Failure to raise
a vehicle from the recommended locations could
result in lifting a vehicle by the hydraulic control
unit mounting bracket. Lifting a vehicle by the
hydraulic control unit mounting bracket will result
in damage to the mounting bracket and the hydrau-
lic control unit.
CAUTION: Brake fluid will damage painted surfaces.
If brake fluid is spilled on any painted surface,
wash off with water immediately.
STANDARD PROCEDURE - ANTILOCK BRAKE
SYSTEM BLEEDING
The base brake's hydraulic system must be bled
anytime air enters the hydraulic system. The ABS
though, particularly the ICU (HCU), should only be
bled when the HCU is replaced or removed from the
vehicle. The ABS must always be bled anytime it is
suspected that the HCU has ingested air. Under
most circumstances that require the bleeding of the
brakes hydraulic system, only the base brake
hydraulic 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 the brake bleeding procedure, be sure the
brake fluid level remains close to the FULL level in
the master cylinder fluid reservoir. Check the fluid
level periodically during the bleeding procedure and
add DOT 3 brake fluid as required.
The ABS must be bled as two independent braking
systems. The non-ABS portion of the brake system
with ABS is to be bled the same as any non-ABS sys-
tem.
The ABS portion of the brake system must be bled
separately. Use the following procedure to properly
bleed the brake hydraulic system including the ABS.
5 - 78 BRAKES - ABSRS
BRAKES - ABS (Continued)
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(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).
(7) Using a brake pedal depressor, move and lock
the brake pedal to a position past the first inch of
pedal travel.This will prevent brake fluid from
draining out of the master cylinder once the
brake tubes are removed from the HCU.
CAUTION: Do not apply a 12±volt power source to
any terminals of the 24-way CAB connector when
disconnected.
(8) Disconnect the wiring harness connector from
the speed control servo.
(9) Remove the speed control servo mounting nuts
and move the servo out of the way.
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 - 90 BRAKES - ABSRS
ICU (INTEGRATED CONTROL UNIT) (Continued)
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(10) Disconnect the 24±way connector from the
CAB. To disconnect the 24±way connector, grasp the
lock on the 24±way connector and pull it as far up as
possible. This will unlock the 24±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.
(11) Thoroughly clean all surfaces of the ICU and
brake tube nuts. Use only a solvent such as Mopart
Brake Parts Cleaner or equivalent to clean the ICU.
(12) Remove the brake tubes (4) from the outlet
ports on the HCU (Fig. 14).
(13) Remove the primary and secondary brake
tubes from the inlet ports on the HCU (Fig. 14).
(14) Center and prop the steering wheel.
(15) Remove the pinch bolt and disconnect the
steering shaft coupling.
(16) If equipped, remove the two clips securing
silencer to dash seal (Fig. 15). Remove silencer.
(17) Remove the three screws securing the dash
seal (Fig. 15). Remove seal.
(18) Remove the 3 bolts attaching the ICU to its
mounting bracket (Fig. 16).
(19) Remove ICU from the vehicle through engine
compartment.
(20) If required, to separating the CAB from the
HCU, (Refer to 5 - BRAKES - ABS/HYDRAULIC/ME-
CHANICAL/ICU (INTEGRATED CONTROL UNIT) -
DISASSEMBLY).
REMOVAL - RHD
NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING)(Refer to 5 - BRAKES - CAUTION)
(1) Disconnect the negative (ground) cable from
the battery and isolate cable.
Fig. 14 Brake Tube Nuts At ICU
1 - PRIMARY BRAKE TUBE
2 - SECONDARY BRAKE TUBE
3 - CHASSIS BRAKE TUBES
Fig. 15 Lower Coupling And Dash Seal
1 - COUPLING
2 - DASH SEAL
3 - SILENCER
4 - MOUNTING SCREWS
5 - RETAINING CLIPS
6 - DASH
Fig. 16 ICU Mounting Bolts
1 - ICU MOUNTING BOLTS
2 - COUPLER
RSBRAKES - ABS5-91
ICU (INTEGRATED CONTROL UNIT) (Continued)
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ASSEMBLY - ICU
(1) Install the CAB (Fig. 24) on the HCU.
(2) Install the 4 bolts mounting the CAB (Fig. 23)
to 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.
(4) Install the ICU in the vehicle and bleed the
base and ABS hydraulic systems. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ICU (INTE-
GRATED CONTROL UNIT) - INSTALLATION)
INSTALLATION
INSTALLATION - LHD
(1) Place the ICU in its bracket below the master
cylinder. Start the upper mounting bolt to hold it in
place.
(2) Inside the vehicle, install the remaining 2
mounting bolts attaching the ICU to the mounting
bracket (Fig. 16). Tighten all 3 mounting bolts to a
torque of 11 N´m (97 in. lbs.).
(3) Install the dash seal and three mounting
screws (Fig. 15).
(4) If equipped, install the silencer on top of the
dash seal (Fig. 15).
(5) Connect the steering shaft coupling and install
the pinch bolt (Fig. 15). Tighten the pinch bolt to 28
N´m (250 in. lbs.).
(6) Remove the steering wheel holder.
CAUTION: Because of the flexible section in the pri-
mary and secondary brake tubes, the brake tubes
must be held in proper orientation when tightened
and torqued. These tubes must not contact eachother or other vehicle components when installed.
Also, after the brake tubes are installed on the HCU,
ensure all spacer clips are reinstalled on the brake
tubes.
(7) Install the primary and secondary brake tubes
into their correct port locations on the HCU valve
block (Fig. 14). Tighten the tube nuts to a torque of
17 N´m (145 in. lbs.).
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.
NOTE: The chassis brake tube attachment locations
to the HCU, are marked on the bottom of the CAB.
(8) Install the (4) chassis brake tubes into their
correct port locations on the HCU valve block as
shown (Fig. 14). Tighten the tube nuts to a torque of
17 N´m (145 in. lbs.).
NOTE: Before installing the 24±way connector in
the CAB be sure the seal is properly installed in the
connector.
(9) Install the 24±way connector on the CAB by,
first, positioning the 24±way connector in the socket
of the CAB and carefully pushing it down as far as
possible. Once connector is fully seated by hand into
the CAB socket, push down on connector lock. This
will pull the connector into the socket of the CAB
and lock it in the installed position.
(10) Install any routing clips on the brake tubes.
(11) Remove the brake pedal holder.
(12) Install the speed control servo with its mount-
ing nuts.
(13) Connect the wiring harness to the speed con-
trol servo.
(14) Install the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - INSTALLA-
TION).
(15) Install the screw securing the coolant filler
neck to the battery tray.
(16) Reconnect the vacuum hose connector at the
tank built into the battery tray.
(17) Install the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION).
(18) Install the battery shield.
(19) Remove the brake pedal holder.
(20) Connect negative cable back on negative post
of the battery.
(21) Bleed the Base and ABS brake hydraulic sys-
tems (Refer to 5 - BRAKES - STANDARD PROCE-
DURE).
Fig. 24 (TYPICAL) Remove/Install CAB
1 - CAB
2 - HCU VALVES
3 - HCU VALVE BLOCK
5 - 94 BRAKES - ABSRS
ICU (INTEGRATED CONTROL UNIT) (Continued)
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(22) Road test vehicle to ensure proper operation
of the base and antilock brake systems.
INSTALLATION - RHD
(1) Install the ICU on the mounting bracket (Fig.
21). Install the 3 bolts (Fig. 21) attaching the ICU to
the mounting bracket. Tighten the 3 mounting bolts
to a torque of 11 N´m (97 in. lbs.).
CAUTION: The ICU 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 ICU bracket to the front suspen-
sion crossmember.
(2) Install the ICU and its mounting bracket as an
assembly on the front suspension crossmember.
Install the 3 bolts attaching the ICU bracket to the
crossmember (Fig. 20). Tighten the 3 mounting bolts
to a torque of 28 N´m (250 in. lbs.).
CAUTION: Because of the flexible section in the pri-
mary 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. 19) for the correct chassis
brake tube locations.
NOTE: The chassis brake tube attachment locations
to the HCU, are marked on the bottom of the ICU
mounting bracket.
(3) Install the 6 chassis brake tubes into their cor-
rect port locations on the HCU valve block as shown
in (Fig. 19). Tighten the tube nuts to a torque of 17
N´m (145 in. lbs.).
NOTE: Before installing the 24-way connector in the
CAB be sure the seal is properly installed in the
connector.(4) Install the 24-way connector (Fig. 17) on the
CAB using the following procedure. Position the
24-way connector in the socket of the CAB and care-
fully push it down as far as possible. When connector
is fully seated by hand into the CAB socket, push in
the connector lock (Fig. 18). This will pull the connec-
tor into the socket of the CAB and lock it in the
installed position.
NOTE: The CAB wiring harness must be clipped to
the ICU 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.
(5) Clip the cab wiring harness (Fig. 17) to the
ICU mounting bracket.
(6) Install the routing clips (Fig. 25) on the brake
tubes.
(7) Lower the vehicle.
(8) Connect negative cable back on negative post of
the battery.
(9) Bleed the base and ABS hydraulic systems.
(Refer to 5 - BRAKES - STANDARD PROCEDURE)
(10) Road test vehicle to ensure proper operation
of the base and antilock brake systems.
Fig. 25 Brake Tube Routing Clips
1 - ROUTING CLIP
2 - HCU
3 - BRAKE TUBES
4 - ROUTING CLIP
RSBRAKES - ABS5-95
ICU (INTEGRATED CONTROL UNIT) (Continued)
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(2) Install clutch release bearing to lever. Apply
grease to interface points. Make sure release bearing
retainers engage lever pocket as shown in (Fig. 10).
(3) Apply grease to pivot ball, and on release lever
at slave cylinder contact point.
(4) Install clutch release bearing/lever assembly
into position by sliding bearing onto input bearing
retainer, and using moderate hand pressure to seat
release lever to pivot ball(s) (Fig. 11). A ªpopº sound
should be heard. Verify proper engagement by lightly
pulling outward on lever at pivot ball location, and
then actuating lever and bearing to ensure proper
operation.
MASTER CYLINDER - RHD
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove master cylinder to clutch pedal pin
retainer clip. Disengage pushrod from clutch pedal
pin (Fig. 13).
(3) Disengage master cylinder grommet from cowl
panel.
(4) Remove battery and tray.
(5)Diesel models:Remove windshield wiper mod-
ule assembly. (Refer to 8 - ELECTRICAL/WIPERS/
WASHERS/WIPER MODULE - REMOVAL)
(6) Discharge Air Conditioning system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
REFRIGERANT - STANDARD PROCEDURE)(7) Remove suction/discharge line from evaporator
junction block.
(8) Using tool 6638A, disconnect clutch hydraulic
ªquick-connectº fitting (Fig. 12).
(9) Remove clutch master cylinder tubing from
retainers in engine compartment.
(10) Remove clutch master cylinder from dash
panel/clutch pedal bracket by rotating 45É clockwise
and pulling outward towards engine (Fig. 13).
(11) Carefully guide clutch master cylinder and
hydraulic plumbing from engine compartment.
Fig. 10 Release Bearing-to-Lever
1 - RETAINER (2)
2 - RELEASE LEVER
3 - RELEASE BEARING
Fig. 11 Release Bearing and Lever
1 - RELEASE LEVER
2 - RELEASE BEARING
Fig. 12 Disconnect Quick-Connect Using Tool 6638A
1 - QUICK CONNECT FITTING
2 - TOOL 6638A
6 - 8 CLUTCHRS
CLUTCH RELEASE LEVER AND BEARING (Continued)
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INSTALLATION
(1) Carefully route master cylinder plumbing into
engine compartment as removed and position master
cylinder to dash panel hole.
(2) Rotate master cylinder 45É clockwise, insert
into dash panel hole, engaging clutch pedal bracket.
Rotate master cylinder 45É counter-clockwise, secur-
ing it to pedal bracket (Fig. 13).
(3) Install and secure grommet to dash panel.
(4) Connect pushrod to clutch pedal pin. Install
retainer clip (Fig. 13).
(5) Secure master cylinder plumbing to retainers
in engine compartment.
(6) Connect clutch master cylinder plumbing to
slave cylinder ªquick connectº fitting. An audible
ªclickº should be heard. Verify connection by pulling
outward.
(7) Connect A/C suction/discharge line to evapora-
tor junction block.
(8)Diesel models:Install wiper module assembly.
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - INSTALLATION)
(9) Install battery and tray.
(10) Connect battery negative cable
(11) Charge Air Conditioning system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE)
MASTER CYLINDER - LHD
REMOVAL
(1) Disconnect battery cables.
(2) Remove instrument panel lower silencer (Fig.
14).
(3) Remove knee bolster (Fig. 15).
(4) Remove clutch master cylinder pushrod
retainer clip (Fig. 16).
(5) Disconnect pushrod from clutch pedal (Fig. 16).
(6) Remove battery shield.
(7) Remove battery.
(8) Remove battery tray.
(9) Remove windshield wiper module assembly
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - REMOVAL).
Fig. 13 Clutch Master Cylinder at Pedal Bracket
1 - CLUTCH MASTER CYLINDER
2 - RETAINER CLIP
3 - CLUTCH PEDAL PIN
4 - PUSH RODFig. 14 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 15 Knee Bolster
1 - KNEE BOLSTER
RSCLUTCH6-9
MASTER CYLINDER - RHD (Continued)
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(10) Using Tool 6638A, disconnect clutch master
cylinder ªquick connectº fitting (Fig. 17). Disengage
plumbing retainer from body stud.
(11) Remove master cylinder reservoir-to-strut
tower nuts (Fig. 18). Reposition reservoir off to side.
(12) Remove clutch master cylinder from dash
panel by rotating clockwise 45É and removing from
dash panel (Fig. 18).(13) Remove master cylinder and plumbing from
engine compartment. Use care not to bend or kink
plumbing. Note plumbing routing to aid in installa-
tion.
INSTALLATION
(1) Install master cylinder into position, while
routing plumbing as originally installed.
(2) Insert master cylinder pushrod through dash
panel (Fig. 18) and rotate 45É counter-clockwise to
secure.
(3) Connect master cylinder plumbing quick-con-
nect fitting. An audible ªclickº should be heard. Ver-
ify connection by pulling outward.
(4) Install master cylinder reservoir onto strut
tower. Install and tighten two (2) master cylinder
reservoir-to-strut tower nuts to 11 N´m (100 in. lbs.)
(Fig. 18).
(5) Install windshield wiper module assembly
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - INSTALLATION).
(6) Install battery tray.
(7) Install battery.
(8) Install battery shield.
(9) Connect master cylinder pushrod to clutch
pedal lever (Fig. 16). Install retainer clip.
(10) Install knee bolster and instrument panel
lower silencer (Fig. 15) (Fig. 14).
(11) Connect battery cables.
Fig. 16 Master Cylinder Pushrod at Pedal
1 - MASTER CYLINDER PUSHROD
2 - CLUTCH/BRAKE PEDAL ASSEMBLY
3 - PUSHROD RETAINER
Fig. 17 Disconnect Quick-Connect Using Tool 6638A
1 - QUICK CONNECT FITTING
2 - TOOL 6638A
Fig. 18 Clutch Master Cylinder Removal/Installation
1 - CLUTCH MASTER CYLINDER
2 - RESERVOIR
3 - NUT (2)
6 - 10 CLUTCHRS
MASTER CYLINDER - LHD (Continued)
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