battery CHRYSLER VOYAGER 1996 User Guide

CAUTION: The master cylinder is used to create
the seal for holding vacuum in the vacuum booster.
The vacuum seal on the master cylinder MUST be
replaced with a NEW seal whenever the master cyl-
inder is removed from the vacuum booster.
CAUTION: When removing the vacuum seal from
the master cylinder do not use a sharp tool.
(7) Using a soft tool such as a trim stick, remove
the vacuum seal from the master cylinder mounting
flange.
(8) Install aNEWvacuum seal on mounting flange
of the master cylinder (Fig. 128).
(9) Position master cylinder on studs of vacuum
booster, aligning push rod on vacuum booster with
master cylinder piston.
(10) Install the 2 nuts mounting the master cylin-
der to the vacuum booster (Fig. 124). Tighten both
mounting nuts to a torque of 25 N´m (225 in. lbs.).
(11) Install the wiper module drain hose (Fig. 124)
on the wiper module. Install the tie strap attaching
the wiper module drain hose to brake tube at the
master cylinder.Tie strap should be loosely tight-
ened so as not to collapse the wiper module
drain hose.
(12) Install the wiring harness connector on the
brake fluid level sensor in the master cylinder fluid
reservoir (Fig. 123).
(13) Install the throttle body and throttle cable
bracket on the intake manifold. Install the 2 bolts
(Fig. 122) attaching the throttle body to the intake
manifold and tighten to a torque of 25 N´m (225 in.
lbs.) Install clip (Fig. 122) attaching the wiring har-
ness to the throttle cable bracket.
(14) Install the wiring harness connectors on the
throttle position sensor and the AIS motor on throttle
body (Fig. 121).(15) Install the wiring harness connector (Fig. 120)
on the EGR valve transducer.
(16) Install the battery tray. Install the 2 bolts and
the nut (Fig. 119) attaching the battery tray to the
vehicle. Tighten the 2 bolts and the nut to a torque of
14 N´m (125 in lbs.).
(17) If vehicle is equipped with speed control,
install the speed control servo and bracket on the
battery tray. Install and securely tighten bolt attach-
ing bracket to battery tray.
(18) If vehicle is equipped with speed control,
install the wiring harness connector on the speed
control servo. Then connect the vacuum lines onto
the speed control servo and vacuum reservoir on bat-
tery tray.
(19) Install the air inlet resonator and hoses as an
assembly on the throttle body and air cleaner hous-
ing (Fig. 118). Securely tighten hose clamp at air
cleaner housing and throttle body.
(20) Install the battery and the battery thermal
guard.
(21) Install the battery cables on the battery.
(22) Check the operation of the stop lamp switch
and adjust if necessary.
JUNCTION BLOCK
REMOVE
(1) Using a brake pedal depressor, move and lock
the brake pedal to a position past its first 1 inch of
travel. This will prevent brake fluid from draining
out of the master cylinder when the brake tubes are
removed from the junction block.
(2) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication And Mainte-
nance Group of this service manual.
CAUTION: Before removing the brake tubes from
the junction block, the junction block and the brake
tubes must be thoroughly cleaned. This is required
to prevent contamination from entering the brake
hudraulic system.
(3) Remove the 6 chassis brake tubes (Fig. 129)
from the junction block.
(4) Remove the bolt (Fig. 130) attaching the junc-
tion block mounting braket to the front suspension
cradle.
INSTALL
(1) Install the junction block and mounting bracket
(Fig. 130) on the front suspension cradle. Install the
attaching bolt and tighten to a torque of 28 N´m (250
in. lbs.).
(2) Install the 6 chassis brake tubes (Fig. 131) into
the inlet and outlet ports of the junction block.
Fig. 128 Vacuum Seal Installed On Master Cylinder
NSBRAKES 5 - 55
REMOVAL AND INSTALLATION (Continued)

INSTALL
(1) Install the hooked end of the actuator on the
proportioning valve lever (Fig. 136).Be sure isola-
tor bushing on lever of proportioning valve
(Fig. 136) is fully seated in hook of actuator.
NOTE: When installing height sensing proportion-
ing valve on mounting bracket be sure proportion-
ing valve shield (Fig. 135) is installed between the
proportioning valve and the mounting bracket.
(2) Install height sensing proportioning valve on
mounting bracket. Install the proportioning valve
attaching bolts (Fig. 135). Tighten the attaching bolts
to a torque of 23 N´m (200 in. lbs.).
(3) Install the 4 chassis brake lines (Fig. 134) into
the inlet and outlet ports of the proportioning valve.
Tighten all 4 line nuts to a torque of 16 N´m (142 in.
lbs.).
(4) Adjust the proportioning valve actuator. See
Height Sensing Proportioning Valve in the Adjust-
ment Section in this group of the service manual for
the adjustment procedure.
(5) Bleed the brake system thoroughly to ensure
that all air has been expelled from the hydraulic sys-
tem. See Bleeding Brake System in the Service
Adjustments section in this group of the service man-
ual for the proper bleeding procedure.
(6) Lower the vehicle to the ground.
(7) Road test the vehicle to verify proper operation
of the vehicles brake system.
HYDRAULIC BRAKE TUBES AND HOSES
CAUTION: When installing brake chassis lines or
flex hoses on the vehicle, the correct fasteners
must be used to attach the routing clips or hoses to
the front suspension cradle. The fasteners used toattach components to the front suspension cradle
have an antiÐcorrosion coating due to the suspen-
sion cradle being made of aluminum. Only Mopar
replacement fasteners with the required anti-corro-
sion coating are to be used if a replacement fas-
tener is required when installing a brake chassis
line or flex hose.
Only double wall 4.75mm (3/16 in.) steel tubing
with Al-rich/ZW-AC alloy coating and the correct tube
nuts are to be used for replacement of a hydraulic
brake tube.
NOTE: On vehicles equipped with traction control,
the primary and secondary hydraulic tubes between
the master cylinder and the hydraulic control unit
are 6 mm (15/64 in.). These tubes are also coated
with the Al-rich/ZW-AC alloy and must be replaced
with tubes having the same anti-corrosion coating.
Be sure that the correct tube nuts are used for the
replacement of these hydraulic brake tubes.
Care should be taken when replacing brake tubing,
to be sure the proper bending and flaring tools and
procedures are used, to avoid kinking. Do not route
the tubes against sharp edges, moving components or
into hot areas. All tubes should be properly attached
with recommended retaining clips.
If the primary or secondary brake tube from the
master cylinder to the ABS Hydraulic Control Unit
(HCU) or the brake tubes from the HCU to the pro-
portioing valve require replacement,onlythe origi-
nal factory brake line containing the flexible section
can be used as the replacement part. This is required
due to cradle movement while the vehicle is in
motion.
PARK BRAKE PEDAL MECHANISM
REMOVE
(1) Disconnect negative (ground) cable from the
battery and isolate cable from battery terminal.
(2) Remove sill scuff plate from left door sill.
(3) Remove the left side kick panel.
(4) Remove the steering column cover from the
lower instrument panel.
(5) Remove the reinforcement from the lower
instrument panel.
(6) Lock out front park brake cable using the fol-
lowing procedure. Grasp the exposed section of the
front park brake cable and pull rearward on it. While
holding the park brake in this position, install a pair
of locking pliers on the front park brake cable just
rearward of the second body outrigger bracket (Fig.
137).
(7) Remove the front park brake cable from the
park brake cable equalizer.
Fig. 136 Actuator Attachment To Proportioning
Valve
5 - 58 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

START-UP CYCLE
The self diagnostic ABS start up cycle begins when
the ignition switch is turned to the on position. Elec-
trical checks are completed on ABS components, such
as the Controller, solenoid continuity, and the system
relay operation. During this check the Amber ABS
Warning Light is turned on for approximately 4 sec-
onds and the brake pedal may emit a popping sound
and move slightly when the solenoid valves are
checked.
DRIVE-OFF CYCLE
Further Functional testing is accomplished once
the vehicle is set in motion and reaches a speed of
about 20 kph (12 mph.). This cycle is performed only
once after each ignition on/off cycle.
²The pump/motor is activated briefly to verify
function. When the pump/motor is activated a whirl-
ing or buzzing sound may be heard by the driver,
which is normal when the pump/motor is running.
²The wheel speed sensor output is verified to be
within the correct operating range.
ONGOING TESTS
Other tests are performed on a continuous basis.
These include checks for solenoid continuity, wheel
speed sensor continuity and wheel speed sensor out-
put.
ABS DIAGNOSTIC TROUBLE CODES
Diagnostic trouble codes (DTC) are kept in the con-
troller's memory until either erased by the technician
using the DRB or erased automatically after 3500
miles. DTC's are retained by the controller even if
the ignition is turned off or the battery is discon-
nected. More than one DTC can be stored at a time.
The mileage of the most recent occurrence, number of
occurrences and the DTC that was stored is also dis-
played. Most functions of the CAB and the ABS sys-
tem can be accessed by the technician for testing and
diagnostic purposes by using the DRB.
LATCHING VERSUS NON-LATCHING
DIAGNOSTIC TROUBLE CODES
Some DTC's detected by the CAB are latching; the
DTC is latched and ABS braking is disabled until the
ignition switch is reset. Thus ABS braking is non
operational even if the original DTC has disappeared.
Other DTC's are non-latching; any warning lights
that are turned on, are only turned on as long as the
DTC condition exists. As soon as the condition goes
away, the ABS Warning Light is turned off, although
a DTC will be set in most cases.
INTERMITTENT DIAGNOSTIC TROUBLE CODES
As with virtually any electronic system, intermit-
tent electrical problems in the ABS system may be
difficult to accurately diagnose.
Most intermittent electrical problems are caused
by faulty electrical connections or wiring. When an
intermittent fault is encountered, check suspect cir-
cuits for:
A visual inspection for loose, disconnected, or mis-
routed wires should be done before attempting to
diagnose or service the ITT Teves Mark 20 antilock
brake system. A visual inspection will eliminate
unnecessary testing and diagnostics time. A thorough
visual inspection will include the following compo-
nents and areas of the vehicle.
(1) Inspect fuses in the power distribution center
(PDC) and the wiring junction block. Verify that all
fuses are fully inserted into the PDC and wring junc-
tion block. A label on the underside of the PDC cover
identifies the locations of the ABS fuses in the PDC.
(2) Inspect the 25-way electrical connector at the
CAB for damage, spread or backed-out wiring termi-
nals. Verify that the 25-way connector is fully
inserted in the socket on the CAB. Be sure that wires
are not stretched tight or pulled out of the connector.
(3) Verify that all the wheel speed sensor connec-
tions are secure.
(4) Poor mating of connector halves or terminals
not fully seated in the connector body.
(5) Improperly formed or damaged terminals. All
connector terminals in a suspect circuit should be
carefully reformed to increase contact tension.
(6) Poor terminal to wire connection. This requires
removing the terminal from the connector body to
inspect.
(7) Pin presence in the connector assembly
(8) Proper ground connections. Check all ground
connections for signs of corrosion, tight fasteners, or
other potential defects. Refer to wiring diagram man-
ual for ground locations.
(9) Problems with main power sources of the vehi-
cle. Inspect battery, generator, ignition circuits and
other related relays and fuses.
(10) If a visual check does not find the cause of the
problem, operate the car in an attempt to duplicate
the condition and record the trouble code.
(11) Most failures of the ABS system will disable
ABS function for the entire ignition cycle even if the
fault clears before key-off. There are some failure
conditions, however, which will allow ABS operation
to resume during the ignition cycle in which a failure
occurred if the failure conditions are no longer
present. The following conditions may result in inter-
mittent illumination of the ABS Warning Lamp. All
other failures will cause the lamp to remain on until
the ignition switch is turned off. Circuits involving
NSBRAKES 5 - 97
DIAGNOSIS AND TESTING (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)

INSTALL
(1) Install the CAB (Fig. 19) on the bottom of the
HCU. Refer to Controller Antilock Brakes (CAB) in
the Removal And Installation Section in this group of
the service manual for the required procedure.
(2) Install the HCU on the mounting bracket (Fig.
23). Install the 3 bolts (Fig. 23) attaching the HCU to
the mounting bracket. Tighten the 3 mounting bolts
to a torque of 11 N´m (97 in. lbs.).
CAUTION: The HCU 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 HCU bracket to the front suspen-
sion crossmember.
(3) Install the HCU and its mounting bracket as
an assembly on the front suspension crossmember.
Install the 3 bolts attaching the HCU bracket to the
crossmember (Fig. 22). Tighten the 3 mounting bolts
to a torque of 28 N´m (250 in. lbs.).
CAUTION: Because of the flexible section in the
primary 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. 21) for the correct chassis
brake tube locations.NOTE: The chassis brake tube attachment loca-
tions to the HCU, are marked on the bottom of the
HCU mounting bracket.
(4) Install the 6 chassis brake tubes into their cor-
rect port locations on the HCU valve block as shown
in (Fig. 21). Tighten the tube nuts to a torque of 17
N´m (145 in. lbs.).
NOTE: Before installing the 25 way connector in
the CAB be sure the seal is properly installed in the
connector.
(5) Install the 25 way connector (Fig. 19) on the
CAB using the following procedure. Position the 25
way connector in the socket of the CAB and carefully
push it down as far as possible. When connector is
fully seated by hand into the CAB socket, push in the
connector lock (Fig. 20). This will pull the connector
into the socket of the CAB and lock it in the installed
position.
NOTE: The CAB wiring harness must be clipped to
the HCU 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.
(6) Clip the cab wiring harness (Fig. 19) to the
HCU mounting bracket.
(7) Install the routing clips (Fig. 24) on the brake
tubes.
(8) Lower vehicle.
(9) Connect negative cable back on negative post of
the battery.
(10) Bleed the base brakes and the ABS brakes
hydraulic system. Refer to the Bleeding ABS System
in this section of the manual for the proper bleeding
procedure.
(11) Road test vehicle to ensure proper operation of
the base and ABS systems.
Fig. 23 HCU Mounting Bolts
Fig. 24 Brake Tube Routing Clips
5 - 102 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

CONTROLLER ANTILOCK BRAKES (CAB)
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
hoist. See Hoisting in the Lubrication And Mainte-
nance section of this service manual.
CAUTION: Do not apply a 12 volt power source to
any terminals of the 25 way HCU connector when
disconnected.
(4) Remove the 25 way connector (Fig. 25) from
the CAB located on the bottom of the HCU. The 25
way connector is removed from the CAB using the
following procedure. Grasp the lock on the 25 way
connector (Fig. 25) and pull it as far out as possible
(Fig. 26). This will unlock and raise the 25 way con-
nector 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.
(5) Thoroughly clean all surfaces of the HCU, and
all brake tube nuts located on the HCU. Use only a
solvent such as Mopar Brake Parts Cleaner or an
equivalent to clean the HCU.
(6) Remove the brake tubes (6) from the inlet and
outlet ports on the HCU. (Fig. 27).(7) Remove the 3 bolts (Fig. 28) attaching the
HCU mounting bracket to the front suspension cross-
member.
Fig. 25 CAB 25 Way Connector
Fig. 26 Unlocking CAB 25 Way Connector
Fig. 27 Brake Tube Connections To HCU
Fig. 28 HCU To Suspension Cradle Mounting Bolts
NSBRAKES 5 - 103
REMOVAL AND INSTALLATION (Continued)

CAUTION: Because of the flexible section in the
primary 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.
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. 27) for the correct chassis
brake tube locations.
NOTE: The chassis brake tube attachment loca-
tions to the HCU, are marked on the bottom of the
HCU mounting bracket.
(6) Install the 6 chassis brake tubes into their cor-
rect port locations on the HCU valve block as shown
in (Fig. 27). Tighten the tube nuts to a torque of 17
N´m (145 in. lbs.).
NOTE: Before installing the 25 way connector in
the CAB be sure the seal is properly installed in the
connector.
(7) Install the 25 way connector on the CAB using
the following procedure. Position the 25 way connec-
tor in the socket of the CAB and carefully push it
down as far as possible. When connector is fully
seated by hand into the CAB socket, push in the con-
nector lock (Fig. 26). This will pull the connector into
the socket of the CAB and lock it in the installed
position.
(8) Install the routing clips (Fig. 33) on the brake
tubes.(9) Lower vehicle.
(10) Connect negative cable back on negative post
of the battery.
(11) Bleed the base brakes and the ABS brakes
hydraulic system. Refer to the Bleeding ABS System
in this section of the manual for the proper bleeding
procedure.
(12) Road test vehicle to ensure proper operation
of the base and ABS brake systems.
WHEEL SPEED SENSOR (FRONT)
REMOVE
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this service man-
ual, for the required lifting procedure to be used for
this vehicle.
(2) Remove the tire and wheel assembly from the
vehicle.
(3) Remove the 2 screws (Fig. 34) attaching front
channel bracket and grommet retainer to the outer
frame rail.
CAUTION: When disconnecting the wheel speed
sensor from vehicle wiring harness, be careful not
to damage pins on connector
(4) Pull speed sensor cable grommet and connector
through the hole in the strut tower (Fig. 35). Discon-
nect speed sensor cable from vehicle wiring harness
(Fig. 35).
(5) Remove the wheel speed sensor head to steer-
ing knuckle attaching bolt (Fig. 36).
(6) Remove sensor head from steering knuckle. If
the sensor has seized, due to corrosion,DO NOT
USE PLIERS ON SENSOR HEAD.Use a hammer
and a punch and tap edge of sensor ear, rocking the
sensor side to side until free.
Fig. 33 Brake Tube Routing Clips
Fig. 34 Front Speed Sensor Cable Channel Bracket
NSBRAKES 5 - 105
REMOVAL AND INSTALLATION (Continued)

the switch is in its normal (fully extended) position.
When the switch is depressed more than 1.25 mm
(0.050), the ohmmeter should show continuity (zero
ohms).
If ohmmeter readings do not fall within these
ranges, the switch is defective, and must be replaced.
CLUTCH PEDAL POSITION
SWITCH±MECHANICAL TEST
With the park brake set and the vehicleIN NEU-
TRAL,turn the key to the start position. The vehicle
should not crank. If the vehicle cranks, the switch is
defective (shorted out) and must be replaced. If the
vehicle does not crank proceed to the next step.
WARNING: BEFORE PERFORMING THIS STEP, BE
SURE THAT THE AREA IN FRONT OF THE VEHICLE
IS CLEAR OF OBSTRUCTIONS AND PEOPLE. VEHI-
CLE MAY MOVE WHEN PERFORMING THIS TEST.With the park brake set and the vehicleIN GEAR,
turn the key to the start position and hold it there.
Slowly depress the clutch pedal and feel for any
vehicle motion when the starter is energized. If there
is no motion the switch is working properly.
If motion is felt, check to see if the switch is mak-
ing contact when the pedal is between 25 mm (1.0
in.) and 6 mm (0.25 in.) from the floor. If this condi-
tion is met, then the problem is either the clutch or
the clutch actuation system (See ªClutch Will Not
Disengage Properlyº). If this condition is not met,
then the switch mounting tab on the brake bracket is
bent, and the brake bracket must be replaced.
If vehicle will not crank, even with clutch pedal
pressed to the floor, refer to ªService Diagnosis-
Clutch Pedal Position Switchº chart in this section.
SERVICE DIAGNOSIS±CLUTCH PEDAL POSITION SWITCH
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WON'T CRANK WHEN
CLUTCH PEDAL IS PRESSED TO
THE FLOORSwitch does not have continuity
when plunger is depressed 1.25 mmDefective switch. Replace switch.
Switch plunger is not depressed
when clutch pedal is pushed to the
floorFloor mat interferes with clutch pedal
movement. Move floor mat out of the
way.
Switch mounting bracket is bent.
Replace brake bracket assembly
Problem is related to other
components in the starting circuitCheck other components in the
starting circuit. Refer to Section 8A,
Battery/Starting/Charging System.
NS/GSCLUTCH 6 - 5
DIAGNOSIS AND TESTING (Continued)

NOTE: Depressing the clutch pedal to the floor pro-
vides access to the clutch cable strand. Disconnect
the cable upstop/spacer from the pedal pivot pin by
removing the retaining clip at the top of the clutch
pedal. Wedge a flat blade pry tool in the clip slot to
remove the clip. Remove the clutch pedal upstop/
spacer from the pedal by wedging a flat blade pry
tool between the spacer and pedal. It may be nec-
essary to push the steel support bracket supporting
the electrical junction block slightly to the left for
clearance to remove the upstop/spacer from the
pedal. Push the cable end fitting out of upstop/
spacer.
CAUTION: Use caution if lifting the clutch pedal
once the clutch pedal/upstop spacer has been
removed. The clutch pedal assist spring provides
enough pedal force to cause an injury. Also, on 2.5L
Turbo Diesel vehicles, lifting the clutch pedal with
the upstop/spacer removed may bend the cruise
control cutout switch bracket located near the top
of the clutch pedal. This will result in non-opera-
tional cruise control.
CAUTION: Do not pull on the clutch cable to
remove it from the dash panel. Damage to the cable
self-adjuster may occur.NOTE: It may be helpful to remove the battery and
clutch cable guide from the left shock tower to
improve access to the clutch cable dash panel
grommet.
Fig. 10 Clutch Cable Routing Ð LHDFig. 11 Clutch Cable Retaining (Upstop) Clip Ð LHD
Fig. 12 Upstop/Spacer Ð LHD
NS/GSCLUTCH 6 - 9
REMOVAL AND INSTALLATION (Continued)