2005 CHRYSLER VOYAGER Page 61

BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE........................... 1BRAKES - ABS........................... 87
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE
DESCRIPTION
DESCRIPTION - BASE BRAKES...........3
DESCRIPTION - BASE BRAKES (EXPORT) . . . 3
OPERATION - BASE BRAKES..............3
WARNING.............................4
CAUTION..............................4
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM.............................4
STANDARD PROCEDURE - BASE BRAKE
BLEEDING............................8
SPECIFICATIONS
BRAKE FASTENER TORQUE.............9
SPECIAL TOOLS
BASE BRAKE SYSTEM.................10
BRAKE FLUID LEVEL SWITCH
DESCRIPTION.........................10
OPERATION...........................10
REMOVAL.............................11
INSTALLATION.........................11
ADJUSTABLE PEDALS SWITCH
REMOVAL.............................11
INSTALLATION.........................11
HYDRAULIC/MECHANICAL
DESCRIPTION
DESCRIPTION - DISC BRAKES (FRONT) . . . 11
DESCRIPTION - DISC BRAKES (REAR)....13
DESCRIPTION - DISC BRAKES (EXPORT) . . 13
DESCRIPTION - DRUM BRAKES (REAR) . . . 13
OPERATION
OPERATION - DISC BRAKES (FRONT).....13
OPERATION - DISC BRAKES (REAR)......14
DIAGNOSIS AND TESTING - DRUM BRAKE
AUTOMATIC ADJUSTER................14
BRAKE LINES
DESCRIPTION - BRAKE TUBES AND HOSES..14
OPERATION - BRAKE TUBES AND HOSES . . . 14INSPECTION - BRAKE TUBES AND HOSES . . . 14
BRAKE PADS/SHOES - FRONT
REMOVAL
REMOVAL - FRONT DISC BRAKE SHOES
(CONTINENTAL TEVES BRAKES).........15
REMOVAL - FRONT DISC BRAKE SHOES
(TRW BRAKES).......................15
CLEANING - DISC BRAKE SHOES..........16
INSPECTION - DISC BRAKE SHOES........16
INSTALLATION
INSTALLATION - FRONT DISC BRAKE
SHOES (CONTINENTAL TEVES BRAKES) . . . 16
INSTALLATION - FRONT DISC BRAKE
SHOES (TRW BRAKES)................17
BRAKE PADS/SHOES - REAR DISC
REMOVAL - REAR DISC BRAKE SHOES.....17
CLEANING - DISC BRAKE SHOES..........18
INSPECTION - DISC BRAKE SHOES........18
INSTALLATION - REAR DISC BRAKE SHOES . . 19
BRAKE PADS/SHOES - REAR DRUM
REMOVAL - REAR DRUM BRAKE SHOES....19
INSPECTION - REAR DRUM BRAKE SHOE
LINING..............................22
INSTALLATION - REAR DRUM BRAKE SHOES..22
ADJUSTMENTS
ADJUSTMENT - REAR DRUM BRAKE
SHOES.............................23
DISC BRAKE CALIPER - FRONT
REMOVAL
REMOVAL - FRONT DISC BRAKE CALIPER
(CONTINENTAL TEVES BRAKES).........24
REMOVAL - FRONT DISC BRAKE CALIPER
(TRW BRAKES).......................24
DISASSEMBLY
DISASSEMBLY - CALIPER GUIDE PIN
BUSHINGS (CONTINENTAL TEVES
BRAKES)............................24
RSBRAKES5-1

BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
DESCRIPTION
DESCRIPTION - ANTILOCK BRAKE
SYSTEM............................87
DESCRIPTION - ANTILOCK BRAKE
SYSTEM (EXPORT)....................87
DESCRIPTION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING...............88
DESCRIPTION - TRACTION CONTROL
SYSTEM............................88
OPERATION
OPERATION - ANTILOCK BRAKE SYSTEM . . 88
OPERATION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING...............89
OPERATION - TRACTION CONTROL
SYSTEM............................89
CAUTION.............................90
STANDARD PROCEDURE - ANTILOCK BRAKE
SYSTEM BLEEDING...................90
SPECIFICATIONS
ABS FASTENER TORQUE...............91
TONE WHEEL RUNOUT................91
WHEEL SPEED SENSOR AIR GAP........91
FRONT WHEEL SPEED SENSOR
REMOVAL.............................91
INSTALLATION.........................92
REAR WHEEL SPEED SENSOR - AWD
REMOVAL.............................92INSTALLATION.........................92
REAR WHEEL SPEED SENSOR - FWD
REMOVAL.............................93
INSTALLATION.........................93
TONE WHEEL
INSPECTION - TONE WHEEL..............94
TRACTION CONTROL SWITCH
DIAGNOSIS AND TESTING - TRACTION
CONTROL SWITCH....................94
REMOVAL.............................95
INSTALLATION.........................95
HYDRAULIC/MECHANICAL
OPERATION - HYDRAULIC CIRCUITS AND
VALVES .............................95
HCU (HYDRAULIC CONTROL UNIT)
DESCRIPTION........................100
OPERATION..........................101
ICU (INTEGRATED CONTROL UNIT)
DESCRIPTION........................102
OPERATION..........................102
REMOVAL
REMOVAL - LHD.....................102
REMOVAL - RHD.....................104
DISASSEMBLY - ICU...................105
ASSEMBLY - ICU......................106
INSTALLATION
INSTALLATION - LHD.................106
INSTALLATION - RHD.................107
BRAKES - ABS
DESCRIPTION
DESCRIPTION - ANTILOCK BRAKE SYSTEM
This section covers the physical and operational
descriptions and the on-car service procedures for the
Mark 20e Antilock Brake System and the Mark 20e
Antilock Brake System with traction control.
The purpose of the antilock brake system (ABS) is
to prevent wheel lockup under braking conditions on
virtually any type of road surface. Antilock braking is
desirable because a vehicle that is stopped without
locking the wheels retains directional stability and
some steering capability. This allows the driver to
retain greater control of the vehicle during braking.
DESCRIPTION - ANTILOCK BRAKE SYSTEM
(EXPORT)
Four-wheel disc antilock brakes are standard on all
models. The Mark 20e antilock brake system is used
on all models. Depending on whether the vehicle is a
left-hand drive (LHD) or right-hand drive (RHD)
model, the integrated control unit (ICU) is located in
one of two locations. On LHD models, the ICU is
mounted above the front suspension cradle/cross-
member below the master cylinder. On RHD models,
the ICU is located behind the front suspension cra-
dle/crossmember on the left side of the vehicle.
RSBRAKES - ABS5-87

For more information, (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ICU (INTEGRATED CON-
TROL UNIT) - DESCRIPTION)
OPERATION
For information on the operation of the HCU as a
whole, refer to Hydraulic Circuits And Valve Opera-
tion which can be found elsewhere in this section.
For information on the operation of the components
within the HCU, refer to the following three topics.
VALVES AND SOLENOIDS
The valve block contains four inlet valves and four
outlet valves. The inlet valves are spring-loaded in
the open position and the outlet valves are spring-
loaded in the closed position during normal braking.
The fluid is allowed to flow from the master cylinder
to the wheel brakes.
During an ABS stop, these valves cycle to maintain
the proper slip ratio for each wheel. The inlet valve
closes preventing further pressure increase and the
outlet valve opens to provide a path from the wheel
brake to the HCU accumulators and pump/motor.
This releases (decays) pressure from the wheel brake,
thus releasing the wheel from excessive slippage.
Once the wheel is no longer slipping, the outlet valve
is closed and the inlet valve is opened to reapply
(build) pressure.
On vehicles with traction control, there is an extra
set of valves and solenoids. The ASR valves, mounted
in the HCU valve block, are normally in the open
position and close only when the traction control is
applied.
These isolator valves are used to isolate the rear
(non-driving) wheels of the vehicle from the hydraulic
pressure that the HCU pump/motor is sending to the
front (driving) wheels when traction control is being
applied. The rear brakes need to be isolated from the
master cylinder when traction control is being
applied so the rear wheels do not drag. For more
information, refer to Traction Control System in this
section.
BRAKE FLUID ACCUMULATORS
There are two fluid accumulators in the HCU±one
for the primary hydraulic circuit and one for the sec-
ondary hydraulic circuit. Each hydraulic circuit uses
a 5 cc accumulator.
The fluid accumulators temporarily store brake
fluid that is removed from the wheel brakes during
an ABS cycle. This stored fluid is used by the pump/
motor to provide build pressure for the brake hydrau-
lic system. When the antilock stop is complete, the
accumulators are drained by the pump/motor.
On ABS-only vehicles, there is a mini-accumulator
on the secondary hydraulic circuit that protects the
master cylinder seals during an ABS stop, and there
is a noise dampening chamber on the primary circuit.
On ABS with traction control vehicles, there are
two noise dampening chambers in the HCU.
PUMP/MOTOR
There are two pump assemblies in the HCUÐone
for the primary hydraulic circuit and one for the sec-
ondary hydraulic circuit. Both pumps are driven by a
common electric motor. This DC-type motor is inte-
gral to the HCU and is controlled by the CAB.
The pump/motor provides the extra amount of
brake fluid needed during antilock braking. Brake
fluid is released to the accumulators when the outlet
valve is opened during an antilock stop. The pump
mechanism consists of two opposing pistons operated
by an eccentric camshaft. In operation, one piston
draws fluid from the accumulators, and the opposing
piston pumps fluid to the master cylinder circuits.
When the antilock stop is complete, the pump/motor
drains the accumulators.
The CAB may turn on the pump/motor when an
antilock stop is detected. The pump/motor continues
to run during the antilock stop and is turned off after
the stop is complete. Under some conditions, the
pump/motor runs to drain the accumulators during
the next drive-off.
The pump/motor is not a serviceable item; if it
requires replacement, the HCU must be replaced.
RSBRAKES - ABS5 - 101
HCU (HYDRAULIC CONTROL UNIT) (Continued)

COOLING
TABLE OF CONTENTS
page page
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM........1
DESCRIPTION - HOSE CLAMPS...........1
OPERATION
OPERATION - COOLING SYSTEM.........2
OPERATION - HOSE CLAMPS............2
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING
SYSTEM LEAK TEST....................2
DIAGNOSIS AND TESTING - COOLING
SYSTEM FLOW CHECK.................3
DIAGNOSIS AND TESTING - COOLING
SYSTEM AERATION....................4
DIAGNOSIS AND TESTING - COOLING
SYSTEM DEAERATION..................4
STANDARD PROCEDURE
STANDARD PROCEDURE - COOLING
SYSTEM DRAINING....................4STANDARD PROCEDURE - COOLING
SYSTEM FILLING......................4
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT.................4
STANDARD PROCEDURE - COOLANT
LEVEL CHECK........................4
SPECIFICATIONS
ACCESSORY DRIVE BELT TENSION.......5
TORQUE.............................5
SPECIAL TOOLS
COOLING SYSTEM.....................6
ACCESSORY DRIVE.......................7
ENGINE...............................13
TRANSMISSION.........................38
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM
The cooling system components consist of a radia-
tor, electric fan motors, shroud, pressure cap, thermo-
stat, transmission oil cooler, water pump, hoses,
clamps, coolant, and a coolant reserve system to com-
plete the circuit.
DESCRIPTION - HOSE CLAMPS
The cooling system uses spring type hose clamps.
If a spring type clamp replacement is necessary,
replace with the original Mopartequipment spring
type clamp.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 1).
Fig. 1 Spring Clamp Size Location
1 - SPRING CLAMP SIZE LOCATION
RSCOOLING7-1

ACCESSORY DRIVE
TABLE OF CONTENTS
page page
DRIVE BELTS
DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT..........................7
CLEANING.............................8
INSPECTION...........................8
DRIVE BELTS - 2.4L
STANDARD PROCEDURE - CHECKING
POWER STEERING BELT TENSION........8
REMOVAL.............................9
INSTALLATION..........................9ADJUSTMENTS........................10
BELT TENSIONER - 2.4L
REMOVAL.............................11
INSTALLATION.........................11
DRIVE BELTS - 3.3/3.8L
REMOVAL.............................11
INSTALLATION.........................12
BELT TENSIONER - 3.3/3.8L
REMOVAL.............................12
INSTALLATION.........................12
DRIVE BELTS
DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT
CONDITION POSSIBLE CAUSES CORRECTIONS
INSUFFICIENT ACCESSORY
OUTPUT DUE TO BELT SLIPPAGE1. Belt too loose 1. (a) Replace belt (auto-tensioned
belts)
(b) Adjust power steering belt
tension (4 cyl. engine)
2. Belt excessively glazed or worn 2. Replace and tighten as specified
BELT SQUEAL WHEN
ACCELERATING ENGINE1. Belts too loose 1. (a) Replace belt (auto-tensioned
belts)
(b) Adjust power steering belt
tension (4 cyl. engine)
2. Belt glazed 2. Replace belts
BELT SQUEAK AT IDLE 1. Belts too loose 1. (a) Replace belt (auto-tensioned
belts)
(b) Adjust power steering belt
tension (4 cyl. engine)
2. Dirt or paint imbedded in belt 2. Replace belt
3. Non-uniform belt 3. Replace belt
4. Misaligned pulleys 4. Align accessories
5. Non-uniform groove or eccentric
pulley5. Replace pulley
RSACCESSORY DRIVE7-7

ENGINE
TABLE OF CONTENTS
page page
ENGINE
DIAGNOSIS AND TESTING - ENGINE
COOLING SYSTEM....................14
CLEANING............................18
INSPECTION..........................18
COOLANT
DESCRIPTION - ENGINE COOLANT.........19
DIAGNOSIS AND TESTING - COOLANT
CONCENTRATION TESTING.............19
STANDARD PROCEDURE - COOLANT
SERVICE............................19
COOLANT RECOVERY CONTAINER
DESCRIPTION.........................20
OPERATION...........................20
DIAGNOSIS AND TESTING - COOLANT
RECOVERY SYSTEM..................20
REMOVAL.............................20
INSTALLATION.........................20
ENGINE BLOCK HEATER
DESCRIPTION.........................20
OPERATION...........................20
DIAGNOSIS AND TESTING - ENGINE BLOCK
HEATER TESTING.....................21
REMOVAL.............................21
INSTALLATION.........................21
ENGINE COOLANT TEMPERATURE SENSOR -
2.4L
DESCRIPTION.........................21
REMOVAL.............................21
INSTALLATION.........................21
ENGINE COOLANT TEMPERATURE SENSOR -
3.3/3.8L
DESCRIPTION.........................21
REMOVAL.............................21
INSTALLATION.........................23
ENGINE COOLANT THERMOSTAT
DESCRIPTION.........................23
OPERATION...........................23
DIAGNOSIS AND TESTING - ENGINE
COOLANT THERMOSTAT...............23
ENGINE COOLANT THERMOSTAT - 2.4L
REMOVAL.............................24
INSTALLATION.........................24
ENGINE COOLANT THERMOSTAT - 3.3/3.8L
REMOVAL.............................24
INSTALLATION.........................25
RADIATOR
REMOVAL.............................26INSTALLATION.........................27
RADIATOR DRAINCOCK
REMOVAL.............................27
INSTALLATION.........................27
RADIATOR PRESSURE CAP
DESCRIPTION.........................27
OPERATION...........................27
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING
SYSTEM PRESSURE CAP TESTING.......28
DIAGNOSIS AND TESTING - RADIATOR
CAP TO FILLER NECK SEAL.............28
CLEANING............................28
INSPECTION..........................29
RADIATOR FAN
DESCRIPTION.........................29
OPERATION...........................29
DIAGNOSIS AND TESTING - RADIATOR FAN
MOTOR .............................30
REMOVAL.............................30
INSTALLATION.........................30
RADIATOR FAN RELAY
DESCRIPTION.........................31
OPERATION...........................31
REMOVAL.............................31
INSTALLATION.........................31
WATER PUMP - 2.4L
DESCRIPTION.........................32
REMOVAL.............................32
CLEANING............................32
INSPECTION..........................32
INSTALLATION.........................32
WATER PUMP - 3.3/3.8L
DESCRIPTION.........................34
REMOVAL.............................34
CLEANING............................35
INSPECTION..........................35
INSTALLATION.........................35
WATER PUMP INLET TUBE - 2.4L
DESCRIPTION.........................36
REMOVAL.............................36
INSTALLATION.........................36
WATER PUMP INLET TUBE - 3.3/3.8L
REMOVAL.............................37
INSTALLATION.........................37
RSENGINE7-13

(8) Remove and discard the seal.
(9) Clean seal groove and sealing surfaces on
pump and timing chain case cover. Take care not to
scratch or gouge sealing surfaces.
CLEANING
Clean gasket mating surfaces as necessary.
INSPECTION
Replace the water pump if it has any of the follow-
ing defects.
(1) Damage or cracks on the pump body.
(2) Coolant leaks; this will be evident by a wet
stream of coolant running down the pump body and
components below. A thin stain below the weep hole
reservoir slot (Fig. 29) is considered normal opera-
tion.(3) Impeller rubs inside of chain case cover.
(4) Excessively loose or rough turning bearing.
NOTE: A weepage stain that is black, brown, or grey
is considered normal, if it is dry. If the weep
appears wet; pressure test the cooling system at
15±18 psi and observe the weep area. If weep area
remains unchanged, do not replace the water pump
for this condition. Replace the water pump, if a
steady flow of engine coolant is evident from the
weep hole/reservoir slot (Fig. 29) (shaft seal failure).
Be sure to perform a thorough analysis before
replacing water pump.
INSTALLATION
(1) Install new seal into water pump housing
groove (Fig. 30).
NOTE: The water pump pulley MUST be positioned
loosely between the pump housing and drive hub
BEFORE water pump installation.
(2) Position the water pump pulley loosely between
pump housing and drive hub (Fig. 27).
(3) Install water pump and pulley to the timing
chain case cover (Fig. 26). Tighten water pump bolts
to 12 N´m (105 in. lbs.).
(4) Position pulley on water pump hub. Install
bolts and tighten to 28 N´m (250 in. lbs.) (Fig. 26).
(5) Rotate pump by hand to check for freedom of
movement.
(6) Install the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
Fig. 27 Water Pump Pulley Positioning
1 - HUB - WATER PUMP
2 - PULLEY - WATER PUMP
Fig. 28 Water Pump Bolts - 3.3/3.8L Engine (Shown
Without Pulley)
1 - WATER PUMP
2 - BOLTS
Fig. 29 Water Pump Inspection - 3.3/3.8L Engine
RSENGINE7-35
WATER PUMP - 3.3/3.8L (Continued)

TRANSMISSION
TABLE OF CONTENTS
page page
TRANSMISSION
STANDARD PROCEDURE - TRANSMISSION
COOLER LINE QUICK CONNECT FITTING
DISASSEMBLY/ASSEMBLY..............38
TRANSMISSION OIL COOLER
DESCRIPTION.........................39INSPECTION..........................39
TRANSMISSION OIL COOLER LINES
REMOVAL.............................39
INSTALLATION.........................40
TRANSMISSION
STANDARD PROCEDURE - TRANSMISSION
COOLER LINE QUICK CONNECT FITTING
DISASSEMBLY/ASSEMBLY
DISCONNECT
(1) Remove dust cap by pulling it straight back off
of quick connect fitting. (Fig. 1)
(2) Place disconnect tool Special Tool 8875A onto
transmission cooler line with the fingers of the tool
facing the quick connect fitting.
(3) Slide disconnect tool down the transmission
line and engage the fingers of the tool into the
retaining clip. When properly engaged in the clip, the
tool will fit flush against the quick connect fitting.
(4) Rotate the disconnect tool 60É to expand the
retaining clip.
(5) While holding the disconnect tool against the
quick connect fitting, pull back on the transmission
cooler line to remove.
CONNECT
(1) Align transmission cooler line with quick con-
nect fitting while pushing straight into the fitting.
(2) Push in on transmission cooler line until a
ªclickº is heard or felt (Fig. 2).
(3) Slide dust cap down the transmission cooler
line and snap it over the quick connect fitting until it
is fully seated and rotates freely (Fig. 2). Dust cap
will only snap over quick connect fitting when the
transmission cooler line is properly installed.
NOTE: If dust cap will not snap into place, repeat
assembly step #2.
Fig. 1 Oil Cooler Line Quick Connect Fitting -
Disassembly
1 - QUICK CONNECT FITTING
2 - DUST CAP
3 - OIL COOLER LINE
4 - SPECIAL TOOL 8875A
7 - 38 TRANSMISSIONRS