lock CHEVROLET DYNASTY 1993 Manual Online

(4) Remove the high and low pressure hose assem-
bly from the pump/motor assembly Fig. 6.
INSTALL
(1) The rubber O-Ring seals used on the high and
low pressure hose connections to the pump/motor as-
sembly. Should be lubricated with clean brake fluid
before connecting hoses to the pump/motor assembly. (2) Position the high and low pressure hose assem-
bly and spray shield on the pump/motor assembly
(Fig. 6). Then install the banjo bolt and torque to 14
N Im (120 in.lbs.)
(3) Carefully route pump/motor assembly wiring
harness along the side of the high and low pressure
hose assembly Fig. 6. (4) Install the 4 tie straps around the hose assem-
bly and wiring harness per the sequence and loca-
tions shown in (Fig. 6). (5) Install the pump/motor assembly back on
mounting bracket, See Pump/Motor Service. (6) Turn the ignition switch to the RUN position.
This will turn on the pump/motor assembly to charge
the high pressure system. (7) Pump the brake system down as detailed in De-
pressurizing Hydraulic Accumulator in this section of
the service manual. (8) Fill the hydraulic assembly to the proper level
with Mopar tbrake fluid or an equivalent meeting
DOT 3 specifications. See Master Cylinder Fluid
Level in the Service Adjustments section of this
group.
HYDRAULIC ASSEMBLY
REMOVE
(1) Fully de-pressurize the hydraulic accumulator
by pumping brake pedal a minimum of 40 times. Use
procedure described in De-Pressurizing Hydraulic Ac-
cumulator listed earlier in this section.
WARNING: FAILURE TO DE-PRESSURIZE HYDRAU-
LIC ACCUMULATOR, BEFORE PERFORMING THIS
OPERATION, MAY RESULT IN PERSONAL INJURY
AND/OR DAMAGE TO PAINTED SURFACES.
(2) Remove fresh air intake duct and air cleaner
from vehicle. (3) Remove the windshield washer fluid bottle
from the vehicle. (4) Disconnect all electrical connectors from the
hydraulic assembly. (5) Remove as much fluid as possible from the res-
ervoir on the hydraulic assembly. (6) Remove pump high pressure hose fitting (Fig.
7) from hydraulic assembly. (7) Disconnect pump return hose from steel tube.
Cap the end of the steel tube. (8) Disconnect the 4 brake tubes from the hydrau-
lic assembly (Fig. 7). (9) From under the instrument panel, position a
small screwdriver between the center tang on the re-
tainer clip and the pin in the brake pedal. Rotate the
screwdriver enough to allow the retainer clip center
tang to pass over the end of the brake pedal pin. Dis-
Fig. 6 Positioning Tie Straps On High And Low Pressure Hose Assembly
Ä ANTI-LOCK 10 BRAKE SYSTEM 5 - 97

card the old retainer clip, a new clip must be
used when hydraulic assembly is reinstalled
(Fig. 8). (10) Remove the 4 hydraulic assembly to dash
panel mounting nuts from the hydraulic assembly
mounting studs, located under instrument panel (Fig.
8). (11) Remove hydraulic assembly from vehicle.
INSTALL (1) Position the hydraulic assembly into its mount-
ing holes on the dash panel of the vehicle. (2) Install and tighten the 4 hydraulic assembly to
dash panel mounting stud nuts (Fig. 8) to 28 N Im
(250 in. lbs.) torque. (3) Using lubriplate or equivalent, coat the bearing
surface of the brake pedal pin. (4) Connect push rod to pedal pin and install a
NEW retainer clip. HYDRAULIC ASSEMBLY
PUSH ROD MUST BE ASSEMBLED TO BRAKE
PEDAL PIN IN THE POSITION AS SHOWN IN
(FIG. 8). (5) If proportioning valves were removed from the
hydraulic assembly, install and torque to 40 N Im (30
ft. lbs.) torque. Then install all 4 brake tubes on the
hydraulic assembly (Fig. 7). Torque the brake tubes
to hydraulic assembly fittings to 16 N Im (145 in.
lbs.). (6) Install return hose on steel tube. Tighten the
return hose clamp to 1 N Im (10 in.lbs.)
Fig. 7 Brake Tube and Hose Routing at Hydraulic
Unit
Fig. 8 Removing or Installing Hydraulic Assembly
5 - 98 ANTI-LOCK 10 BRAKE SYSTEM Ä

(7) Install high pressure hose to hydraulic assem-
bly (Fig. 7). Tighten the hose, to hydraulic assembly
fitting to 16 N Im (145 in. lbs)
(8) Fill hydraulic assembly brake fluid reservoir to
top of screen on the reservoir filter/strainer Fig. 9.
(9) Connect all electrical connectors to the hydrau-
lic assembly. (10) Bleed the entire brake system, see Bleeding
Brake System in this section of the Service Manual. (11) Replace all fresh air intake ducts, air cleaner
and washer bottle. (12) Check that the brake fluid in the hydraulic
assembly is at the correct level before moving vehicle
(Fig. 9). (See Checking Brake Fluid Level in this sec-
tion of the service manual).
BRAKE FLUID RESERVOIR
REMOVE
(1) Fully de-pressurize the hydraulic accumulator
by pumping brake pedal a minimum of 40 times. Use
procedure described in De-Pressurizing Hydraulic Ac-
cumulator listed earlier in this section.
WARNING: FAILURE TO DE-PRESSURIZE HYDRAU-
LIC ACCUMULATOR, BEFORE PERFORMING THIS
OPERATION, MAY RESULT IN PERSONAL INJURY
AND/OR DAMAGE TO PAINTED SURFACES.
(2) Remove as much brake fluid as possible from
the fluid reservoir, using a syringe or equivalent
method. (3) Using Oil Filter Band Wrench, Special Tool
C-4065 or equivalent loosen bladder accumulator. Then remove the bladder accumulator and brake
fluid spray shield from the hydraulic assembly (Fig.
10). Remove high pressure banjo fitting from hydrau-
lic assembly.
(4) Using needle nose pliers, remove the three
fluid reservoir retaining pins from the hydraulic as-
sembly (Fig. 11). Compress the barb on the opposite
side of retaining pin to prevent pin from breaking.
(5) Remove reservoir from hydraulic assembly by
CAREFULLY prying between reservoir and hydrau-
Fig. 9 ABS Fill Level On Filter/Strainer
Fig. 10 Removing Bladder Accumulator
Fig. 11 Remove Reservoir Retaining Pins
Ä ANTI-LOCK 10 BRAKE SYSTEM 5 - 99

lic assembly with a blunt prying tool (Fig. 12). Use a
rocking motion to help disengage reservoir from
grommets while prying. BE EXTREMELY CARE-
FUL TO AVOID DAMAGING OR PUNCTURING
RESERVOIR DURING THIS PROCEDURE.
(6) Remove the brake fluid level sensor switch
from the reservoir. Remove switch by compressing
the retaining barbs (Fig. 13) on the end of the switch
and then slide switch out of the brake fluid reservoir
(Fig. 14) (7) Using fingers, remove the 3 reservoir grommets
(Fig. 14) from the hydraulic assembly or reservoir, and
discard. Grommets must not to be reused when
reservoir is installed on hydraulic assembly.
INSTALL (1) Thoroughly lubricate the new reservoir grom-
mets with clean brake fluid and install on reservoir
outlet ports (Fig. 14). The new reservoir grommets
supplied with reservoir, must ALWAYS be used. (2) Install brake fluid level switch into brake fluid
reservoir (FIG. 14). (3) Press reservoir into hydraulic assembly BY
HAND , using a rocking motion to help seat reservoir
into hydraulic assembly. Be sure that grommets are
fully seated in the hydraulic assembly. DO NOT AT-
TEMPT TO POUND RESERVOIR INTO HY-
DRAULIC ASSEMBLY, USING A HAMMER. (4) Using needle nose pliers, install the 3 brake fluid
reservoir to hydraulic assembly retaining pins (Fig.
11). Make sure that pins are fully installed with barbs
extending past reservoir on opposite side. (5) Reinstall the high pressure hose, banjo fitting
onto the hydraulic assembly and torque the fitting to
13 N Im (10.0 ft.lbs).
(6) Install the brake fluid spray shield and bladder
accumulator onto the hydraulic assembly. Install the
bladder accumulator by hand to be sure it does not bet
cross threaded. Be sure that the O-Ring on the
bladder accumulator is fully seated into the hy-
draulic assembly. (7) Using Oil Filter Band Wrench, Special Tool C-
4065 or equivalent, (Fig. 10) torque the bladder accu-
mulator to 48 N Im (35 ft. lbs.)
Fig. 12 Remove Reservoir From Hydraulic Assembly
Fig. 13 Fluid Switch Retaining Barbs
Fig. 14 Remove Brake Fluid Level Switch
5 - 100 ANTI-LOCK 10 BRAKE SYSTEM Ä

(8) Fill the hydraulic assembly reservoir to the top
of the screen on the filter/strainer (Fig. 15). Using
fresh clean brake fluid such as Mopar tor equivalent,
conforming to DOT 3 requirements.
PUMP SUPPLY FILTER
REMOVE
(1) Fully de-pressurize the hydraulic accumulator
by pumping brake pedal a minimum of 40 times. Use
procedure described in De-Pressurizing Hydraulic Ac-
cumulator listed earlier in this section.
WARNING: FAILURE TO DE-PRESSURIZE HYDRAU-
LIC ACCUMULATOR, BEFORE PERFORMING THIS
OPERATION, MAY RESULT IN PERSONAL INJURY
AND/OR DAMAGE TO PAINTED SURFACES.
(2) Remove and then reinstall one filler cap from
brake fluid reservoir on hydraulic assembly. (3) Remove brake fluid supply hose from hydraulic
assembly master cylinder at the pump supply filter
(Fig. 16). After hose is removed from pump supply
filter, plug end of hose to stop brake fluid from drain-
ing out of fluid reservoir. (4) Remove brake fluid supply hose (Fig. 16), from
pump supply filter going to the pump motor assem-
bly. (5) Remove pump supply filter (Fig. 16) from at-
taching bracket on front of hydraulic assembly.
INSTALL (1) Attach pump supply filter to attaching bracket
on front of hydraulic assembly (Fig. 16). (2) Install replacement hose clamp, on brake fluid
supply hose to pump motor assembly. (3) Install the brake fluid supply hose to pump mo-
tor assembly, onto the nipple of the pump supply fil-
ter. Position hose clamp on brake fluid supply hose
so that it is past upset bead on nipple, then torque
hose clamp to 1.5 N Im (13.5 in. lbs.).
(4) Remove plug from brake fluid supply hose com-
ing from hydraulic assembly. Install the brake fluid
supply hose from hydraulic assembly, onto the nipple
of the pump supply filter. Position hose clamp on
brake fluid supply hose so that it is past upset bead
on nipple, then torque hose clamp to 1.5 N Im (13.5
in. lbs.). (5) Turn ignition switch to the run position to en-
ergize the pump/motor assembly and pressurize hy-
draulic system. Check for leakage at the hydraulic
assembly to hydraulic bladder accumulator fitting. (6) Again de-pressurize accumulator by pumping
brake pedal a minimum of 40 times as described. Use
procedure in De-Pressurizing Hydraulic Accumulator
in this section of the manual. (7) Then check the brake fluid level in the hydrau-
lic assembly reservoir. If brake fluid level is low, fill
reservoir to proper level (Fig. 15) with Mopar tbrake
fluid or equivalent conforming to DOT 3 require-
ments.
HYDRAULIC BLADDER ACCUMULATOR
REMOVE
(1) Fully de-pressurize the hydraulic accumulator
by pumping brake pedal a minimum of 40 times. Use
procedure described in De-Pressurizing Hydraulic Ac-
cumulator listed earlier in this section.
Fig. 15 ABS Reservoir Fill Level On Filter/Strainer
Fig. 16 Pump Supply Filter
Ä ANTI-LOCK 10 BRAKE SYSTEM 5 - 101

WARNING: FAILURE TO DE-PRESSURIZE HYDRAU-
LIC ASSEMBLY/ACCUMULATOR PRIOR PERFORM-
ING THIS OPERATION. MAY RESULT IN PERSONAL
INJURY AND/OR DAMAGE TO PAINTED SURFACES
OF THE VEHICLE.
(2) Using Oil Filter Band Wrench, Special Tool
C-4065 or equivalent loosen bladder accumulator.
Then remove the bladder accumulator and brake
fluid shield from the hydraulic assembly (Fig. 17).
INSTALL
(1) Install the brake fluid spray shield onto the hy-
draulic accumulator (Fig. 1). (2) Install the bladder accumulator onto the hy-
draulic assembly by hand. Be sure that the O-Ring
on the bladder accumulator is fully seated into the
hydraulic assembly. (3) Using Oil Filter Band Wrench, Special Tool
C-4065 or equivalent, (Fig. 17) torque the bladder ac-
cumulator to 48 N Im (35 ft. lbs.)
(4) Turn ignition switch to the run position to en-
ergize the pump/motor assembly and pressurize hy-
draulic system. Check for leakage at the hydraulic
assembly to hydraulic bladder accumulator fitting. (5) Again de-pressurize accumulator by pumping
brake pedal a minimum of 40 times. Use procedure
described in De-Pressurizing Hydraulic Accumulator
in this section of the service manual. (6) Then check the brake fluid level in the hydrau-
lic assembly reservoir. If brake fluid level is low, fill
reservoir to proper level (Fig. 15) with Mopar tbrake
fluid or equivalent conforming to DOT 3 require-
ments.PROPORTIONING VALVES (FIG. 18)
CAUTION: Proportioning valves should never be dis-
assembled or repaired in any way, repair is by re-
placement only.
REMOVE (1) Fully de-pressurize the hydraulic accumulator by
pumping brake pedal a minimum of 40 times. Use
procedure described in De-Pressurizing Hydraulic Ac-
cumulator listed earlier in this section.
WARNING: FAILURE TO FULLY DE-PRESSURIZE THE
HYDRAULIC ASSEMBLY/ACCUMULATOR PRIOR TO
REMOVING THE PROPORTIONING VALVE. MAY RE-
SULT IN PERSONAL INJURY AND/OR DAMAGE TO
PAINTED SURFACES OF THE VEHICLE.
(2) Remove fresh air intake ducts and air cleaner.
(3) Remove pressure and return hose (Fig. 5) from
hydraulic unit. (See Pressure and Return Hose Section
For Proper Removal Procedure). (4) Remove brake tube from the proportioning valve
that requires servicing. (5) Remove proportioning valve requiring service
from the hydraulic assembly (Fig. 19).
INSTALL (1) Install proportioning valve on hydraulic assem-
bly and tighten to 40 N Im (30 ft. lbs.) torque.
(2) Install brake tube on proportioning valve.
Tighten tube nut to 16 N Im (145 in. lbs.) torque.
(3) Install hydraulic pressure and return hoses.
Torque pressure hose to hydraulic assembly fitting to
16 N Im (145 in. lbs). Torque return hose to metal tube
hose clamp to 1 N Im (10 in. lbs.).
(4) Install fresh air intake duct and air cleaner.
(5) Bleed the affected brake line, see Bleeding Brake
System in this section.
Fig. 17 Remove And Install Bladder Accumulator
Fig. 18 ABS Proportioning Valve
5 - 102 ANTI-LOCK 10 BRAKE SYSTEM Ä

ELECTRONIC COMPONENTS
CONTROLLER ANTI-LOCK BRAKE (CAB)
REMOVAL (1) Turn vehicle ignition off.
(2) Raise vehicle on hoist, (CAB) access for re-
moval is from the underside of the vehicle (Fig. 1) (3) Remove transmission oil cooler line routing
clip. (4) Disconnect the wiring harness 60 way connec-
tor from the Controller Anti-Lock Brake Module
(CAB). VERIFY THAT THE VEHICLE IGNI-
TION IS OFF BEFORE REMOVING THE 60
WAY CONNECTOR. (5) Remove the 3 (CAB) module to frame rail
mounting bolts. (6) Remove the (CAB) module from the vehicle.
INSTALLATION (1) Install the (CAB) module back in the vehicle.
(2) Install the 3 (CAB) module to frame rail at-
taching bolts. Torque the 3 (CAB) module to frame
rail attaching bolts to 5 N Im (40 in. lbs.).
(3) VERIFY THAT THE VEHICLE IGNITION
IS OFF BEFORE CONNECTING THE 60 WAY
CONNECTOR. Connect the wiring harness 60 way
connector into the (CAB) module until it is fully seated. Torque the 60 way connector to (CAB) mod-
ule retaining bolt to 12 N Im (105 in. lbs.).
Fig. 19 Hydraulic Assembly
Fig. 1 Location Controller Anti-Lock Brake (CAB)
Ä ANTI-LOCK 10 BRAKE SYSTEM 5 - 103

SYSTEM RELAY, ANTI-LOCK WARNING LAMP RELAY AND PUMP/MOTOR RELAYS (FIG. 2)
REMOVE
See (Fig. 2) Power Distribution Center. Find the lo-
cation of the pump/motor relay in the (PDC). Remove
pump/motor relay by pulling upward and install by
pushing firmly into position. Do not twist the relay
when removing or installing it. See (Fig. 10) in the Relay And Warning Lamp Sec-
tion of this group, for the location of the Anti-Lock
system relay and the Yellow Lamp relay. Remove
the relay from the vehicle using the following proce-
dure. (1) Disconnect the wiring harness connectors from
the relays. Connectors are removed from the relays
by disengaging the connector locking tab from relay
and pulling strait off relay, do not twist. (2) Then remove the relay pack to inner fender at-
taching bolt.
INSTALL The Anti-Lock system and Yellow Lamp relay are
installed using the following procedure. (1) Mount the relay pack to the inner fender with
the anti-rotation tab on the bracket around lip of in-
ner fender hole (Fig. 10). (2) Install the relay pack to inner fender mounting
bolt and torque to 4 N Im (35 in. lbs.). (3) Connect the wiring harness connectors onto the
relays until the locking tabs on the connectors and
relays are fully engaged. Do not twist connectors when
installing them on the relays.
WHEEL SPEED SENSORS
INSPECTION
Inspect tone wheels (Fig. 3) for any missing or broken
teeth, this can cause erratic speed sensor signals.
Tone wheels should show no evidence of contact with
the wheel speed sensor. If contact was made, determine
cause and correct. Excessive runout of the tone wheels can cause erratic
wheel speed sensor signals. Replace assembly if runout
exceeds approximately 0.25 mm (0.010 inch).
FRONT WHEEL SPEED SENSOR
REMOVAL
(1) Raise vehicle and remove front wheel and tire
assembly. (2) Remove screw from clip (Fig. 4) that holds sensor
assembly grommet into fender shield. (3) Carefully, pull sensor assembly grommet from
fender shield. When removing grommet from
fender shield, do not pull on speed sensor cable. (4) Unplug speed sensor cable connector, from ve-
hicle wiring harness. (5) Remove the 2 screws (Fig. 4) that secure the
speed sensor cable, routing tube to the fender well. (6) Remove the 2 sensor assembly grommets from
the retainer bracket, on the strut damper (Fig. 4). (7) Remove speed sensor assembly to steering
knuckle attaching bolt (Fig. 4). (8) Carefully, remove sensor head from steering
knuckle. If the sensor has seized, due to corrosion, use
a hammer and punch to tap edge of sensor ear
Fig. 2 Pump/Motor and Anti-Lock System Relays
Fig. 3 Tone Wheel (Typical)
5 - 104 ANTI-LOCK 10 BRAKE SYSTEM Ä

(Fig. 5), rocking the sensor side to side until free. DO
NOT USE PLIERS ON SENSOR HEAD.
INSTALLATION (1) Connect the wheel speed sensor cable connec-
tor, to the vehicle wiring harness. (2) Push sensor assembly grommet into hole in
fender shield. Install clip and screw (Fig. 4). Torque
screw to 4 N Im (35 in. lbs.).
(3) Install speed sensor cable grommets in bracket
on strut damper (Fig. 4). (4) Install speed sensor cable routing tube to fender
well (Fig. 4). Torque both screws to 4 N Im (35 in. lbs.).
(5) Coat the speed sensor with High Temperature
Multi-purpose E.P. Grease before installing into the
steering knuckle. Install speed sensor attaching screw
and tighten to 7 N Im (60 in. lbs.)
CAUTION: Proper installation of wheel speed sensor
cables is critical to continued system operation. Be
sure that cables are routed correctly and installed in
all retainers. Failure to properly route and install
cables in retainers, as shown in this section. May
result in contact with moving parts and/or over ex-
tension of cables, resulting in an open circuit.
REAR WHEEL SPEED SENSOR (FIGS. 6 AND 8)
REMOVAL
(1) Raise vehicle and remove wheel and tire assem-
bly. (2) Remove sensor assembly grommet from under-
body and pull harness through hole in underbody. (3) Unplug connector from harness.
(4) Remove sensor grommet bracket screw from
body hose bracket, just forward of trailing arm bush-
ing. (5) Remove sensor assembly clip, located on the
inboard side of trailing arm. (6) Remove sensor wire fastener from rear brake
hose bracket. (7) Remove outboard sensor assembly retainer nut.
(8) Remove sensor head screw.
(9) Carefully, remove sensor head from adapter as-
sembly. If the sensor has seized, due to corrosion, DO
NOT USE PLIERS ON SENSOR HEAD. Use a ham-
mer and a punch (Fig. 7) and tap edge of sensor ear,
rocking the sensor side to side until free.
INSTALLATION
Installation is reverse order of removal. Be sure to
coat sensor with High Temperature Multi-purpose E.P.
Grease before installing into adapter assembly.
Tighten screw to 7 N Im (60 in. lbs.) torque. Avoid
getting grease on the pickup area of the speed sensor
assembly.
Fig. 4 Front Wheel Speed Sensor Routing
Fig. 5 Removing Speed Sensor (Typical)
Ä ANTI-LOCK 10 BRAKE SYSTEM 5 - 105

DUAL FUNCTION PRESSURE SWITCH
REMOVE
WARNING: FAILURE TO DE-PRESSURIZE THE HY-
DRAULIC ACCUMULATOR PRIOR TO REMOVING
DUAL FUNCTION PRESSURE SWITCH. WILL RESULT
IN PERSONAL INJURY AND/OR DAMAGE TO
PAINTED SURFACES OF THE VEHICLE. CAUTION: THOROUGHLY CLEAN THE BOTTOM OF
THE HYDRAULIC ASSEMBLY IN THE AREA OF THE
DUAL FUNCTION PRESSURE SWITCH, BEFORE RE-
MOVING THE SWITCH FROM HYDRAULIC ASSEM-
BLY. USE MOPAR BRAKE PARTS CLEANER OR AN
EQUIVALENT. EXTREME CARE MUST BE USED SO
NO DIRT IS ALLOWED TO ENTER THE HYDRAULIC
ASSEMBLY THROUGH WHERE THE DUAL FUNC-
TION PRESSURE SWITCH IS MOUNTED. ANY DIRT
ENTERING HYDRAULIC ASSEMBLY MAY PLUG IN-
TERNAL PASSAGES CAUSING A HYDRAULIC AS-
SEMBLY FAILURE.
(1) Fully de-pressurize the hydraulic accumulator by
pumping brake pedal a minimum of 40 times. Use
procedure described in De-Pressurizing Hydraulic Ac-
cumulator listed earlier in this section. (2) Raise vehicle See Hoisting, Group 0.
(3) From under vehicle, disconnect wiring harness
connectors from dual function pressure switch and
boost pressure transducer (Fig. 9) on the bottom of
hydraulic assembly.
WARNING: WEAR EYE PROTECTION WHEN PER-
FORMING THE FOLLOWING PROCEDURE. SERIOUS
EYE INJURY CAN RESULT FROM BRAKE FLUID
CONTACTING THE EYES.
(4) Be sure that the hydraulic system is de-
pressurized. Remove the dual function pressure
switch from the hydraulic assembly using Socket,
Special Tool 6607 (Fig. 10). Access to the switch is from
under the vehicle using a long extension.
Fig. 6 Rear Wheel Speed Sensor Routing at Trailing Arm
Fig. 7 Removing Speed Sensor (Typical)
5 - 106 ANTI-LOCK 10 BRAKE SYSTEM Ä