servo CHRYSLER VOYAGER 1996 Owner's Manual

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)

Before test driving a brake complaint vehicle, note
whether the Red or Amber Brake Warning Lamp is
turned on. If it is the Red Brake Warning Lamp,
refer to the hydraulic system section in the brake
group of this manual. If the ABS Warning lamp
was/is on, test drive the vehicle as described below, to
verify the complaint. While the ABS Warning Lamp
is on, the ABS is not functional. The standard brake
system and the ability to stop the car may not be
affected if only the ABS Warning Lamp is on.
Discuss with the owner of the vehicle or note any
other electrical problems or conditions that may be
occurring on the vehicle. They may have an effect on
the antilock brake system's function.
(1) Turn the key to the off position and then back
to the on position. Note whether the ABS Warning
Lamp continues to stay on. If it does, refer to the
diagnostic manual covering the ITT Teves Mark 20
ABS system for the required test procedures.
(2) If the ABS Warning Lamp goes out, shift into
gear and drive the car to a speed of 20 kph (12 mph)
to complete the ABS start up cycle. If at this time the
ABS Warning Lamp goes on refer to the ITT Teves
Mark 20 Diagnostic Manual.
(3) If the ABS Warning Lamp remains OUT, drive
the vehicle a short distance. During this test drive be
sure that the vehicle achieves at least 40 mph. Brake
to at least one complete stop in an ABS cycle, and
again accelerate to 25 mph.
(4) If a functional problem with the ABS system is
determined while test driving a vehicle, refer to the
diagnostic manual covering the ITT Teves Mark 20
ABS system for the required test procedures and
proper use of the DRB diagnostic scan tool.
ABS SERVICE PRECAUTIONS
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.In testing for open or short circuits, do
not ground or apply voltage to any of the cir-
cuits unless instructed to do so for a diagnostic
procedure.These circuits should only be tested
using a high impedance multi-meter or the DRB
tester 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: Use only factory wiring harnesses. Do
not cut or splice wiring to the brake circuits. The
addition of after-market electrical equipment (car
phone, radar detector, citizen band radio, trailer
lighting, trailer brakes, ect.) on a vehicle equippedwith antilock brakes may affect the function of the
antilock brake system.
SERVICE PROCEDURES
BRAKE FLUID LEVEL INSPECTION
CAUTION: Use only Mopar brake fluid or an equiv-
alent from a tightly sealed container. Brake fluid
must conform to DOT 3 specifications. Do not use
petroleum-based fluid because seal damage in the
brake system will result.
For the specific procedure covering the inspection
of the brake fluid level and adding brake fluid to the
reservoir, refer to the Service Adjustments Section in
this group of the service manual.
BLEEDING TEVES MARK 20 HYDRAULIC SYSTEM
The base brake system must be bled anytime air is
permitted to enter the hydraulic system, due to dis-
connection of brake lines, hoses or components. The
ABS system, particularly the HCU, should only be
bled when the HCU is replaced or removed from the
vehicle, or if there is reason to believe the HCU has
ingested air. Under most circumstances that would
require brake bleeding, only the base brake 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 bleeding operations, be sure that the brake
fluid level remains close to the FULL level in the res-
ervoir. Check the fluid level periodically during the
bleeding procedure and add DOT 3 brake fluid as
required.
The Teves Mark 20 ABS hydraulic system and the
base brake hydraulic system must be bled as two
independent braking systems. The non ABS portion
of the brake system is to be bled the same as any
non ABS system. Refer to the Service Adjustments
section in this manual for the proper bleeding proce-
dure to be used. This brake system can be either
pressure bled or manually bled.
The ABS portion of the brake system MUST be
bled separately. This bleeding procedure requires the
use of the DRB Diagnostic Tester and the bleeding
sequence procedure outlined below.
ABS BLEEDING PROCEDURE
When bleeding the ABS system, the following
bleeding sequenceMUSTbe followed to insure com-
plete and adequate bleeding. The ABS system can be
bled using a manual bleeding procedure or standard
pressure bleeding equipment.
NSBRAKES 5 - 99
DIAGNOSIS AND TESTING (Continued)

If the brake system is to be bled using pressurized
bleeding equipment, refer to Bleeding Brake System
in the Service Adjustments section at the beginning
of this group for proper equipment usage and proce-
dures.
(1) Assemble and install all brake system compo-
nents on the vehicle making sure all hydraulic fluid
lines are installed and properly torqued.
(2) Connect the DRB Diagnostics Tester to the
diagnostics connector. The Teves Mark 20 ABS diag-
nostic connector is located under the instrument
panel to the left of the steering column cover.
(3) Using the DRB, check to make sure the CAB
does not have any fault codes stored. If it does,
remove them using the DRB.
WARNING: WHEN BLEEDING THE BRAKE SYS-
TEM WEAR SAFETY GLASSES. A CLEAR BLEED
TUBE MUST BE ATTACHED TO THE BLEEDER
SCREWS AND SUBMERGED IN A CLEAR CON-
TAINER FILLED PART WAY WITH CLEAN BRAKE
FLUID. DIRECT THE FLOW OF BRAKE FLUID AWAY
FROM THE PAINTED SURFACES OF THE VEHICLE.
BRAKE FLUID AT HIGH PRESSURE MAY COME
OUT OF THE BLEEDER SCREWS WHEN OPENED.
(4) Bleed the base brake system using the stan-
dard pressure or manual bleeding procedure as out-
lined in the Service Adjustments section of this
service manual.
(5) Using the DRB, go to the9Bleed ABS9routine.
Apply the brake pedal firmly and initiate the9Bleed
ABS9cycle one time. Release the brake pedal.
(6) Bleed the base brake system again, as in step
Step 4 above.
(7) Repeat steps Step 5 and Step 6 above until
brake fluid flows clear and is free of any air bubbles.
Check brake fluid level in reservoir periodically to
prevent reservoir from running low on brake fluid.
(8) Test drive the vehicle to be sure brakes are
operating correctly and that brake pedal is solid.
REMOVAL AND INSTALLATION
ABS GENERAL SERVICE PRECAUTIONS
CAUTION: Review this entire section prior to per-
forming any mechanical work on a vehicle equipped
with the ITT Tevis Mark 20 ABS brake system. This
section contains information on precautions per-
taining to potential component damage, vehicle
damage and personal injury which could result
when servicing an ABS equipped vehicle.
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: Certain components of the ABS System
are not intended to be serviced individually.
Attempting to remove or disconnect certain system
components may result in improper system opera-
tion. Only those components with approved
removal and installation procedures in this manual
should be serviced.
CAUTION: Brake fluid will damage painted sur-
faces. If brake fluid is spilled on any painted sur-
faces, wash off with water immediately.
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 CAB. Doing this will damage the pump
motor and will require replacement of the HCU.
The following are general cautions which should be
observed when servicing the ABS system and/or
other vehicle systems. Failure to observe these pre-
cautions may result in ABS System component dam-
age.
If welding work is to be performed on the vehicle,
using an electric arc welder, the CAB connector
should be disconnected during the welding operation.
The CAB 25 way connector connector should never
be connected or disconnected with the ignition switch
in the ON position.
Many components of the ABS System are not ser-
viceable and must be replaced as an assembly. Do not
disassemble any component which is not designed to
be serviced.
HYDRAULIC CONTROL UNIT
REMOVE
(1) Disconnect the negative (ground) cable from
the battery and isolate cable.
(2) 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 when the
brake tubes are removed from the HCU.
(3) Raise vehicle. Vehicle is to be raised and sup-
ported on jackstands or on a frame contact type
5 - 100 BRAKESNS
SERVICE PROCEDURES (Continued)

The clutch pedal on the 2.0L is fitted with a return
spring (Fig. 3). The spring hook that attaches to the
pedal is coated with nylon. Push the hook all the way
through the hole in the pedal to prevent it from
walking out. No service lubrication is required.
The clutch pedal on the 2.4L and 2.5L VM diesel is
fitted with an assist spring (Fig. 4) to reduce clutch
pedal effort. The assist spring has two plastic end fit-
tings which locate to pins on the clutch pedal and
bracket. The plastic which the fittings are made of
includes PTFE lubricant. No service lubrication is
required.
HYDRAULIC LINKAGE AND COMPONENTS Ð
RHD
The hydraulic clutch linkage is a prefilled system
free of air, contamination, and leaks. There is no rou-
tine maintenance required. The hydraulic clutch link-
age is serviced as an assembly and the individual
components cannot be overhauled or serviced sepa-
rately. The hydraulic linkage consists of a clutch
master cylinder with integral reservoir, a clutch slave
cylinder and an interconnecting fluid line with quick
disconnect coupling (Fig. 5).
The clutch master cylinder push rod is connected
to the clutch pedal (Fig. 6). The clutch pedal is fitted
with a return spring. The spring hook that attaches
to the pedal is coated with nylon. No service lubrica-
tion is necessary. The slave cylinder push rod is con-
nected to the clutch release fork (Fig. 5).
Fig. 2 Clutch Pedal Components Ð LHD
Fig. 3 Clutch Pedal Return Spring Ð 2.0L LHD
Fig. 4 Assist Spring Ð 2.4L and 2.5L VM Diesel LHD
6 - 2 CLUTCHNS/GS
GENERAL INFORMATION (Continued)

(2) Install water pump pulley.
(3) Install drive belt, Refer to Accessory Drive
Belts, this Group. Tighten water pump pulley attach-
ing bolts to 27.5 N´m (240 in. lbs.)
(4) Install right inner splash shield.
(5) Refill cooling system. Refer to Refilling Cooling
System in this Group.
ENGINE THERMOSTATÐ 2.0L GASOLINE
REMOVAL
(1) Drain cooling system to the thermostat level or
below.
(2) Remove coolant recovery system (CRS) hose
and thermostat/engine outlet connector bolts.
(3) Remove thermostat and seal, and clean sealing
surfaces.
INSTALLATION
(1) Place the new thermostat assembly into the
thermostat housing/outlet connector. Align air bleed
vent with notch in cylinder head.
(2) Install thermostat housing/outlet connector
onto cylinder head and tighten bolts to 12.5 N´m (110
in. lbs.). Connect the upper radiator hose.
(3) Refill cooling system (seeRefilling System).
THERMOSTAT Ð 2.5L VM DIESEL
REMOVAL
(1) Drain cooling system down below the thermo-
stat level. Refer to Draining Cooling System in this
section.(2) Remove radiator hose at thermostat cover.
(3) Remove thermostat cover bolts (Fig. 20).
(4) Remove Thermostat.
INSTALLATION
(1) Remove old gasket material from thermostat
housing and cover.
(2) Install new thermostat gasket.
(3) Install thermostat and tighten cover bolts to
10.8 N´m (96 in. lbs.).
(4) Install radiator hose.
(5) Refill cooling system. Refer to Refilling Cooling
System in this section.
RADIATOR Ð 2.5L VM DIESEL
REMOVAL
(1) Disconnect battery.
(2) Remove power steering reservoir attaching
bolts, and reposition reservoir.
(3) Remove radiator closure panel crossmember
(Fig. 21).
(4) Remove air cleaner housing and intake hose.
(5) Unplug fan module 4 pin wiring connector.
(6) Drain cooling system. Refer to Draining cooling
system in this section for procedure.
(7) Remove upper and lower Radiator Hoses.
(8) Remove radiator attaching bolts.
(9) Loosen A/C receiver/dryer lower bolt.
(10) Remove Radiator.
(11) Remove fan module from radiator.
Fig. 19 Water Pump Drive BeltÐ 2.5 L VM Diesel
Fig. 20 Thermostat and Housing Ð 2.5L VM Diesel
NS/GSCOOLING SYSTEM 7 - 9
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Install fan module on radiator.
(2) Install radiator.
(3) Tighten receiver/dryer lower bolt.
(4) Install radiator attaching bolts.
(5) Install lower and upper radiator hoses.
(6) Connect fan module.
(7) Install air cleaner housing and intake hose.
(8) Install radiator closure panel crossmember.
(9) Install power steering reservoir attaching bolts.
(10) Refill cooling system. Refer to Refilling cooling
system in this section for procedure.
(11) Connect battery.
WATER PUMP BELT Ð 2.5L VM DIESEL
REMOVAL
(1) Remove generator/power steering belt. Refer to
procedure in this section.
(2) Raise vehicle on hoist.
(3) Remove right side splash shield (Fig. 22).
(4) Loosen belt tensioner bracket bolts (Fig. 23).(5) Loosen adjuster lock nut.
(6) Loosen adjusting bolt, and remove belt.
INSTALLATION
(1) Install water pump belt.
(2) Turn adjusting bolt clockwise to tighten belt.
(3) Tighten lock nut.
(4) Tighten belt tensioner bracket bolts
(5) Lower vehicle.
(6) Install generator/power steering belt. Refer to
procedure in this section.
GENERATOR/POWER STEERING BELT Ð 2.5L VM
DIESEL
REMOVAL
(1) Loosen generator pivot bolt (Fig. 24).
(2) Loosen adjusting bracket bolt.
(3) Loosen adjusting nut.
(4) Remove generator/power steering belt.
INSTALLATION
(1) Install generator/power steering belt.
(2) Tighten adjusting nut.
(3) Tighten adjusting bracket bolt.
(4) Tighten generator pivot bolt.
CLEANING AND INSPECTION
WATER PUMP
Replace the water pump if it has any of the follow-
ing defects.
(1) Damage or cracks on the pump body.
Fig. 21 Radiator Closure Panel Crossmember
Fig. 22 Right Side Splash Shield
Fig. 23 Water Pump Belt Removal Ð 2.5L VM Diesel
7 - 10 COOLING SYSTEMNS/GS
REMOVAL AND INSTALLATION (Continued)

(3) Place battery heat shield over battery. The top
inside surface of heat shield must be flush with top
of battery.
(4) Connect battery cable terminals, positive cable
first. Make sure the top of battery terminals are
flush with top of posts.
WARNING: DO NOT OVER TIGHTEN BATTERY
CABLE CLAMPS, DAMAGE TO CLAMPS CAN
RESULT.(5) Tighten terminal nuts to 8.5 N´m (75 in. lbs.).
BATTERY TRAY
REMOVAL
(1) Remove battery, refer to the above procedures.
(2) Remove nut and two bolts from battery tray
(Fig. 18).
(3) Remove battery tray from vehicle.
(4) Remove speed control servo attaching bolt from
battery tray (if equipped). Use care when disconnect-
ing vacuum lines from reservoir (Fig. 19).
INSTALLATION
For installation, reverse the above procedures.
Fig. 16 Battery Hold Down
Fig. 17 Remove Battery
Fig. 18 Battery Tray Removal
NSBATTERY 8A - 9
REMOVAL AND INSTALLATION (Continued)

SPECIFICATIONS
BATTERY SPECIFICATIONS
CRANKING RATING
The current battery can deliver for 30 seconds and
maintain a terminal voltage of 7.2 volts or greater at
specified temperature.
RESERVE CAPACITY RATING
The length of time a battery can deliver 25 amps
and maintain a minimum terminal voltage of 10.5
volts at 27ÉC (80ÉF).
TORQUE
DESCRIPTION TORQUE
Battery Hold Down Bolt Clamp
Bolt....................14N´m(125 in. lbs.)
Fig. 19 Speed Control Servo Removal
Load Test
(Amps)Cold Cranking
Rating @ 0ÉFReserve
Capacity
250 Amp 500 Amp 110 Minutes
300 Amp 600 Amp 120 Minutes
340 Amp 685 Amp 125 Minutes
8A - 10 BATTERYNS
REMOVAL AND INSTALLATION (Continued)

(4) Tighten terminal nuts to 8.5 N´m (75 in. lbs.).
BATTERY TRAY
REMOVAL
(1) Remove battery, refer to the above procedures.
(2) Remove nut and two bolts from battery tray
(Fig. 19).
(3) Remove battery tray from vehicle.
(4) Remove speed control servo attaching bolt from
battery tray (if equipped). Use care when disconnect-
ing vacuum lines from reservoir (Fig. 20).
INSTALLATION
For installation, reverse the above procedures.
SPECIFICATIONS
BATTERY SPECIFICATIONS
CRANKING RATING
The current battery can deliver for 30 seconds and
maintain a terminal voltage of 7.2 volts or greater at
specified temperature.
Fig. 16 Battery Cable Disconnected
Fig. 17 Battery Hold Down
Fig. 18 Remove Battery
Fig. 19 Battery Tray Removal
NS/GSBATTERY 8A - 9
REMOVAL AND INSTALLATION (Continued)

TORQUE
DESCRIPTION TORQUE
Battery Hold Down Bolt Clamp
Bolt...................14N´m(125 in. lbs.)
Fig. 20 Speed Control Servo Removal
Reserve Cold Cranking Reserve
(Amps) Rating @ -17.8C (0.0F) Capacity
DIN/BCI
200 Amp 500 Amp 110
Minutes
250 Amp 600 Amp 120
Minutes
315 Amp 685 Amp 125
Minutes
8A - 10 BATTERYNS/GS
SPECIFICATIONS (Continued)