Egr CHRYSLER VOYAGER 1996 Service Manual

DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
TOWING RECOMMENDATIONS
WARNINGS AND CAUTIONS
WARNING: DO NOT ALLOW TOWING ATTACH-
MENT DEVICES TO CONTACT THE FUEL TANK OR
LINES, FUEL LEAK CAN RESULT.
DO NOT LIFT OR TOW VEHICLE BY FRONT OR
REAR BUMPER, OR BUMPER ENERGY ABSORBER
UNITS.
DO NOT GO UNDER A LIFTED VEHICLE IF NOT
SUPPORTED PROPERLY ON SAFETY STANDS.
DO NOT ALLOW PASSENGERS TO RIDE IN A
TOWED VEHICLE.
USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-
tem, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle.
Do not attach towing device to front or rear sus-
pension components.
Do not secure vehicle to towing device by the use
of front or rear suspension or steering components.
Remove or secure loose or protruding objects
from a damaged vehicle before towing.
Refer to state and local rules and regulations
before towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use of a flat bed towing device or wheel lift (Fig. 2) is
recommended. When using a wheel lift towing device,
be sure the disabled vehicle has at least 100 mm (4
in.) ground clearance. If minimum ground clearance
cannot be reached, use a towing dolly. If a flat bed
device is used, the approach angle should not exceed
15 degrees.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels
removed, install lug nuts to retain brake drums or
rotors.
A towed vehicle should be raised until the lifted
wheels are a minimum 100 mm (4 in.) from the
ground. Be sure there is at least 100 mm (4 in.)
clearance between the tail pipe and the ground. If
necessary, remove the wheels from the lifted end of
the vehicle and lower the vehicle closer to the
ground, to increase the ground clearance at the rear
of the vehicle. Install lug nuts on wheel attaching
studs to retain brake drums or rotors.
LOCKED VEHICLE TOWING
When a locked vehicle must be towed with the
front wheels on the ground, use a towing dolly or flat
bed hauler.
FLAT TOWING WITH TOW BAR
²3-speed automatic transaxle vehicles can be flat
towed at speeds not to exceed 40 km/h (25 mph) for
not more than 25 km (15 miles). The steering column
must be unlocked and gear selector in neutral.
²4-speed electronic automatic transaxle vehicles
can be flat towed at speeds not to exceed 72 km/h (44
mph) for not more than 160 km (100 miles). The
steering column must be unlocked and gear selector
in neutral.
FLAT BED TOWING TIE DOWNS
CAUTION: Do not tie vehicle down by attaching
chains or cables to suspension components or
engine mounts, damage to vehicle can result.
NS vehicles can be tied to a flat bed device using
the reinforced loops located under the front and rear
bumpers on the drivers side of the vehicle. There are
also four reinforced elongated holes for T or R-hooks
located on the bottom of the front frame rail torque
Fig. 2 Recommended Towing Devices
0 - 8 LUBRICATION AND MAINTENANCENS
SERVICE PROCEDURES (Continued)

JUMP STARTING, HOISTING AND TOWING
INDEX
page
SERVICE PROCEDURES
TOWING RECOMMENDATIONS............. 5
SERVICE PROCEDURES
TOWING RECOMMENDATIONS
WARNINGS AND CAUTIONS
WARNING: DO NOT ALLOW TOWING ATTACH-
MENT DEVICES TO CONTACT THE FUEL TANK OR
LINES, FUEL LEAK CAN RESULT.
DO NOT LIFT OR TOW VEHICLE BY FRONT OR
REAR BUMPER, OR BUMPER ENERGY ABSORBER
UNITS.
DO NOT GO UNDER A LIFTED VEHICLE IF NOT
SUPPORTED PROPERLY ON SAFETY STANDS.
DO NOT ALLOW PASSENGERS TO RIDE IN A
TOWED VEHICLE.
USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-
tem, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle.
Do not attach towing device to front or rear sus-
pension components.
Do not secure vehicle to towing device by the use
of front or rear suspension or steering components.
Remove or secure loose or protruding objects
from a damaged vehicle before towing.
Refer to state and local rules and regulations
before towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use of a flat bed towing device or wheel lift (Fig. 1) is
recommended. When using a wheel lift towing device,
be sure the disabled vehicle has at least 100 mm (4
in.) ground clearance. If minimum ground clearance
cannot be reached, use a towing dolly. If a flat bed
device is used, the approach angle should not exceed
15 degrees.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels
removed, install lug nuts to retain brake drums or
rotors.
A towed vehicle should be raised until the lifted
wheels are a minimum 100 mm (4 in.) from the
ground. Be sure there is at least 100 mm (4 in.)
clearance between the tail pipe and the ground. If
necessary, remove the wheels from the lifted end of
the vehicle and lower the vehicle closer to the
ground, to increase the ground clearance at the rear
of the vehicle. Install lug nuts on wheel attaching
studs to retain brake drums or rotors.
LOCKED VEHICLE TOWING
When a locked vehicle must be towed with the
front wheels on the ground, use a towing dolly or flat
bed hauler.
FLAT TOWING WITH TOW BAR
²4-speed electronic automatic transaxle vehicles
can be flat towed at speeds not to exceed 72 km/h (44
mph) for not more than 160 km (100 miles). The
steering column must be unlocked and gear selector
in neutral.
FLAT BED TOWING TIE DOWNS
CAUTION: Do not tie vehicle down by attaching
chains or cables to suspension components or
engine mounts, damage to vehicle can result.
Fig. 1 Recommended Towing Devices
NS/GSLUBRICATION AND MAINTENANCE 0 - 5

Camber adjustment is allowed in the event that a
vehicle is involved in an accident and after repairs
are made meeting manufacturers tolerance specifica-
tions, the camber setting will not meet manufactur-
ers specifications. If camber adjustment is required,
refer to the following Service Camber Adjustment
Procedure for the required steps to be followed.
CAUTION: Do not attempt to modify any suspen-
sion or steering components to meet vehicle align-
ment specifications, by heating and or bending.
Alignment checks and adjustments should be made
in the following sequence.
(1) Camber
(2) ToeCamberis the number of degrees the top of the
wheel and tire assembly is tilted inboard or outboard
from a true vertical line. Inboard tilt is negative cam-
ber. Outboard tilt is positive camber (Fig. 1).
Excessive camber is a tire wear factor: negative
camber causes wear on the inside of the tires tread
surface, while positive camber causes wear to the
outside of the tires tread surface. See Front Wheel
Drive Specifications forCamber.settings.
To eis measured in degrees or inches and is the
distance the front edges of the tires are closer (or far-
ther apart) than the rear edges. See Front Wheel
Drive Specifications forToe.settings.
Fig. 1 Front Suspension Alignment Angles
2 - 2 SUSPENSIONNS
DESCRIPTION AND OPERATION (Continued)

* Camber is adjustable using the Mopar Camber Adjustment Service Kit. Refer to the Mopar
Parts Catalog for the required service kit part number.
** Caster is not adjustable. If found to be out of specification check for proper ride heights and
damaged/worn out suspension components and replace as necessary.
*** Toe-In is positive.
**** Toe, Camber and thrust angle are not adjustable. If found to be out of specification check for
proper ride heights and damaged/worn out suspension components and replace as necessary.
***** When Measuring ride heights: 1) Ensure that the tire pressures are correct. 2) Jounce the vehicle at the
bumper several times and release at the bottom of the stroke. 3) Measure from the ground to the outboard, lower,
center section of the fender wheel well opening. Ride heights are not adjustable. If found to be out of specification
check for damaged and/or worn out suspension components and replace as necessary.
ALIGNMENT ANGLE TIRE SIZES TIRE SIZES ALTERNATIVE FUELS
P205/75/R14 P205/75/R15 C.N.G.
P215/65/R15 P215/65/R16 ELECTRIC
* FRONT INDIVIDUAL CAMBER IN
DEGREES............................................+0.15É +or- 0.40É +0.05É +or- 0.40É +0.15É +or- 0.40É
Front Side To Side Camber
Difference Not To Exceed...................0.00É - 0.50É MAX 0.00É - 0.50É MAX 0.00É - 0.50É MAX
** FRONT INDIVIDUAL CASTER IN
DEGREES............................................+1.40É + or - 1.00É +1.40É + or - 1.00É +1.40É +or- 1.00É
Front Side To Side Caster Difference
Not To
Exceed.....................................0.00É - 1.00É MAX 0.00É - 1.00É MAX 0.00É - 1.00É MAX
*** FRONT INDIVIDUAL TOE
RIGHT/
LEFT.........................................+0.05É+or- 0.10É +0.05É +or- 0.10É +0.05É +or- 0.10É
FRONT TOTAL
TOE....................................................
Specified In Degrees+0.10É +or- 0.20É +0.10É +or- 0.20É +0.10É +or- 0.20É
FRONT SIDE TO SIDE TOE
DIFFERENTIAL.....................................0.00É - 0.06É MAX 0.00É - 0.06É MAX 0.00É - 0.06É MAX
****REAR INDIVIDUAL CAMBER IN
DEGREES............................................+0.00É +or- 0.25É +0.00É +or- 0.25É -0.10É +or- 0.25
REAR INDIVIDUAL TOE RIGHT/
LEFT........................................0.00É +or- 0.40É 0.00É +or- 0.40É 0.00É +or- 0.40É
**** REAR TOTAL TOE.....................
Specified In Degrees
TOE OUT: When Backed On
Alignment Rack Is TOE In When
Driving0.00É +or- 0.40É 0.00É +or- 0.40É 0.00É +or- 0.40É
****REAR THRUST ANGLE................ 0.00É +or- 0.30É 0.00É +or- 0.30É 0.00É +or- 0.30É
STEERING WHEEL
ANGLE................0.00É +or- 2.50É 0.00É +or- 2.50É 0.00É +or- 2.50É
FRONT RIDE HEIGHT (MEASURED
AT TOP OF FENDER WHEEL
OPENING)............................................747.5 mm +or-10.0mm 753.5 mm +or-10.0mm 783.5 mm +or-10.0mm
FRONT RIDE HEIGHT SIDE TO
SIDE
DIFFERENTIAL.....................................0.0 mm 12.5 mm MAX 0.0 mm 12.5 mm MAX 0.0 mm 12.5 mm MAX
*****REAR RIDE HEIGHT
(MEASURED AT TOP OF FENDER
WHEEL
OPENING)............................................766.0 mm +or-10.0mm 772.0 mm +or-10.0mm 802.5 mm +or-10.0mm
*****REAR RIDE HEIGHT SIDE TO
SIDE
DIFFERENTIAL.....................................0.0 mm 12.5 mm MAX 0.0 mm 12.5 mm MAX 0.0 mm 12.5 mm MAX
2 - 8 SUSPENSIONNS
SPECIFICATIONS (Continued)

ALIGNMENT ANGLE TIRE SIZES TIRE SIZESALTERNATIVE
FUELS
P205/75/R14 P205/75/R15 C.N.G.
P215/65/R15 P215/65/R16 ELECTRIC
* FRONT INDIVIDUAL CAMBER IN
DEGREES............................................+0.15É +or- 0.40É +0.05É +or- 0.40É +0.15É +or- 0.40É
Front Side To Side Camber Difference Not
To Exceed...................0.00É - 0.50É MAX 0.00É - 0.50É MAX 0.00É - 0.50É MAX
** FRONT INDIVIDUAL CASTER IN
DEGREES............................................+1.40É + or - 1.00É +1.40É + or - 1.00É +1.40É +or- 1.00É
Front Side To Side Caster Difference Not To
Exceed.....................................0.00É - 1.00É MAX 0.00É - 1.00É MAX 0.00É - 1.00É MAX
*** FRONT INDIVIDUAL TOE RIGHT/
LEFT.........................................+0.05É+or- 0.10É +0.05É +or- 0.10É +0.05É +or- 0.10É
FRONT TOTAL
TOE....................................................
Specified In Degrees+0.10É +or- 0.20É +0.10É +or- 0.20É +0.10É +or- 0.20É
FRONT SIDE TO SIDE TOE
DIFFERENTIAL.....................................0.00É - 0.06É MAX 0.00É - 0.06É MAX 0.00É - 0.06É MAX
****REAR INDIVIDUAL CAMBER IN
DEGREES............................................+0.00É +or- 0.25É +0.00É +or- 0.25É -0.10É +or- 0.25
REAR INDIVIDUAL TOE RIGHT/
LEFT........................................0.00É +or- 0.40É 0.00É +or- 0.40É 0.00É +or- 0.40É
**** REAR TOTAL TOE.....................
Specified In Degrees
TOE OUT: When Backed On Alignment Rack
Is TOE In When Driving0.00É +or- 0.40É 0.00É +or- 0.40É 0.00É +or- 0.40É
****REAR THRUST ANGLE................ 0.00É +or- 0.30É 0.00É +or- 0.30É 0.00É +or- 0.30É
STEERING WHEEL ANGLE................ 0.00É +or- 2.50É 0.00É +or- 2.50É 0.00É +or- 2.50É
FRONT RIDE HEIGHT (MEASURED AT
TOP OF FENDER WHEEL
OPENING)............................................747.5 mm
+or-10.0mm753.5 mm
+or-10.0mm783.5 mm
+or-10.0mm
FRONT RIDE HEIGHT SIDE TO SIDE
DIFFERENTIAL.....................................0.0 mm 12.5 mm
MAX0.0 mm 12.5 mm
MAX0.0 mm 12.5 mm
MAX
*****REAR RIDE HEIGHT (MEASURED AT
TOP OF FENDER WHEEL
OPENING)............................................766.0 mm
+or-10.0mm772.0 mm
+or-10.0mm802.5 mm
+or-10.0mm
*****REAR RIDE HEIGHT SIDE TO SIDE
DIFFERENTIAL.....................................0.0 mm 12.5 mm
MAX0.0 mm 12.5 mm
MAX0.0 mm 12.5 mm
MAX
2 - 2 SUSPENSIONNS/GS
SPECIFICATIONS (Continued)

FIXED PROPORTIONING VALVE OPERATION
The fixed proportioning valve is made out of alumi-
num and has an integral mounting bracket. The
fixed proportioning valve is non-serviceable compo-
nent and must be replaced as an assembly if found to
be functioning improperly.
The fixed proportioning valve is mounted to the
bottom of the left rear frame rail, just forward of the
rear shock absorber to frame rail mounting location
(Fig. 6). The proportioning valve has 2 inlet ports for
brake fluid coming from the ABS modulator, and 2
outlet ports for brake fluid going to the rear wheel
brakes.
The fixed proportioning valve operates by allowing
full hydraulic pressure to the rear brakes up to a set
point, called the valve's split point. Beyond this split
point the proportioning valve reduces the amount of
hydraulic pressure to the rear brakes according to a
certain ratio.
Thus, on light brake pedal applications the propor-
tioning valve allows approximately equal brake
hydraulic pressure to be supplied to both the front
and rear brakes. On heavier brake pedal applications
though, the proportioning valve will control hydraulic
pressure to the rear brakes, so that hydraulic pres-
sure at the rear brakes will be lower than that at the
front brakes. This controlled hydraulic pressure to
the rear brakes prevents excessive rear wheel ABS
cycling during moderate stops.
HEIGHT SENSING PROPORTIONING VALVE
CAUTION: The use of after-market load leveling or
load capacity increasing devices on this vehicle are
prohibited. Using air shock absorbers or helper
springs on this vehicle will cause the height sens-
ing proportioning valve to inappropriately reduce
the hydraulic pressure to the rear brakes. This inap-
propriate reduction in hydraulic pressure potentiallycould result in increased stopping distance of the
vehicle.
On vehicles not equipped with ABS brakes, the
brake systems hydraulic control unit (HCU) is
replaced by a junction block (Fig. 7). The junction
block is made of aluminum and is mounted to the
front suspension crossmember on the drivers side of
the vehicle in the same location as the (HCU) on an
ABS equipped vehicle. The junction block is perma-
nently attached to its mounting bracket and must be
replaced as an assembly with its mounting bracket.
The junction block is used for diagonally splitting the
brake's hydraulic system.
Vehicles not equipped with ABS brakes use a
height sensing proportioning valve. The height sens-
ing proportioning valve is mounted on the left frame
rail at the rear of the vehicle (Fig. 8). The height
sensing proportioning valve uses an actuator assem-
bly (Fig. 8) to attach the proportioning valve to the
left rear spring for sensing changes in vehicle height.
HEIGHT SENSING PROPORTIONING VALVE OPERATION
The height sensing proportioning valve regulates
the hydraulic pressure to the rear brakes. The pro-
portioning valve regulates the pressure by sensing
the load condition of the vehicle through the move-
ment of the proportioning valve actuator assembly
Fig. 6 Fixed Proportioning Valve Location
Fig. 7 Junction Block Location
Fig. 8 Height Sensing Proportioning Valve
5 - 6 BRAKESNS
DESCRIPTION AND OPERATION (Continued)

(11) Install the wiring harness connector on the
brake fluid level sensor in the master cylinder fluid
reservoir (Fig. 113).
(12) Install the battery tray in the vehicle. Install
the 2 bolts and the nut (Fig. 112) attaching the bat-
tery tray to the vehicle. Tighten the 2 bolts and the
nut to a torque of 14 N´m (125 in lbs.).
(13) 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.
(14) 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.
(15) Install the air inlet resonator and hoses as an
assembly on the throttle body and air cleaner hous-
ing (Fig. 111). Securely tighten the hose clamp at the
air cleaner housing and throttle body.
(16) Install the battery and the battery thermal
guard.
(17) Install the battery cables on the battery.
(18) Check the operation of the stop lamp switch
and adjust if necessary.
VACUUM BOOSTER 3.3/3.8 LITER ENGINE
REMOVE
CAUTION: Reserve vacuum in the vacuum booster
must be pumped down (removed) before removing
master cylinder from vacuum booster. This is nec-
essary to prevent the vacuum booster from sucking
in any contamination as the master cylinder is
removed. This can be done simply by pumping the
brake pedal, with the vehicle's engine not running,
until a firm feeling brake pedal is achieved.
(1) With engine not running, pump the brake
pedal until a firm pedal is achieved (4-5 strokes).
(2) Remove both battery cables from battery.
(3) Remove the battery thermal guard and the bat-
tery from the battery tray.
(4) Remove the air inlet resonator and hoses as an
assembly from the throttle body and air cleaner
housing (Fig. 118)
(5) If vehicle is equipped with speed control,
unplug wiring harness connector from the speed con-
trol servo. Then disconnect vacuum lines from the
speed control servo and vacuum reservoir on battery
tray.
(6) Remove bolt attaching the speed control servo
bracket to the battery tray. Slide the bracket forward
to unhook it from the battery tray and remove.
(7) Remove the 2 bolts and the nut (Fig. 119)
attaching the battery tray to the body of the vehicle.(8) Remove the wiring harness connector (Fig. 120)
from the EGR valve transducer.
(9) Remove wiring harness connectors from throt-
tle position sensor and AIS motor on throttle body
(Fig. 121).
(10) Remove the 2 bolts (Fig. 122) attaching the
throttle body to the intake manifold and the clip (Fig.
122) attaching the wiring harness to the throttle
cable bracket. Then remove the throttle body and
throttle cable bracket as an assembly from the intake
manifold.
(11) Remove wiring harness connector from brake
fluid level sensor in master cylinder fluid reservoir
(Fig. 123).
(12) Clean the area where the master cylinder
assembly attaches to the power brake booster. Use
Fig. 118 Air Inlet Resonator
Fig. 119 Battery Tray Mounting Locations
5 - 52 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

only a solvent such as Mopar Brake Parts Cleaner or
an equivalent.
(13) Remove clip, attaching drain hose for wiper
module to brake tube at master cylinder. Remove
drain hose (Fig. 124) from wiper module. Remove the
2 nuts, attaching the master cylinder to the vacuum
booster (Fig. 124).
NOTE: It is not necessary to remove the brake
tubes from the master cylinder when removing the
master cylinder from the vacuum booster.
(14) Remove master cylinder and brake tubes as
an assembly from the vacuum booster. When mastercylinder is removed, lay it out of the way on top of
the left motor mount
Fig. 120 Electrical Connector At EGR Transducer
Fig. 121 Electrical And Vacuum Connections To
Throttle Body
Fig. 122 Throttle Body Attachment To Intake
Manifold
Fig. 123 Fluid Level Sensor Electrical Connection
Fig. 124 Master Cylinder Attachment To Vacuum
Booster
NSBRAKES 5 - 53
REMOVAL AND INSTALLATION (Continued)

(15) Remove the EGR Valve and the vacuum
transducer (Fig. 125) as an assembly from the intake
manifold.
(16) Disconnect vacuum hose from check valve
located on vacuum booster.DO NOT REMOVE
CHECK VALVE FROM POWER BRAKE
BOOSTER.
(17) Locate the vacuum booster input rod to brake
pedal connection under the instrument panel. Posi-
tion a small screwdriver between the center tang on
the power brake booster input rod to brake pedal pin
retaining clip (Fig. 126).
(18) Rotate screwdriver enough to allow retaining
clip center tang to pass over end of brake pedal pin.
Then pull retaining clip off brake pedal pin.Discard
retaining clip. It is not to be reused. Replace
only with a new retaining clip when assem-
bling.
(19) Remove the 4 nuts attaching the power brake
vacuum booster to the dash panel. Nuts are accessi-ble from under dash panel in area of the steering col-
umn and pedal bracket assembly.
(20) From outside the vehicle, slide power brake
vacuum booster forward until its mounting studs
clear dash panel. Then tilt the booster up and toward
the center of vehicle to remove.
CAUTION: Do not attempt to disassemble the
power brake vacuum booster it is to be serviced
ONLY as a complete assembly.
INSTALL
CAUTION: When installing the power brake vacuum
booster in the vehicle be sure the heater hoses do
not become trapped between the booster and the
dash panel of the vehicle.
(1) Position vacuum booster on dash panel using
the reverse procedure of its removal.
(2) Install the 4 nuts mounting the vacuum
booster to the dash panel. Tighten the 4 mounting
nuts to a torque of 29 N´m (250 in. lbs.).
(3) Using lubriplate, or an equivalent, coat the sur-
face of the brake pedal pin where it contacts the vac-
uum booster input rod.
CAUTION: When installing the brake pedal pin on
the power brake vacuum booster input rod, do not
re-use the old retaining clip.
(4) Install vacuum booster input rod on brake
pedal pin and install aNEWretaining clip (Fig. 127).
(5) Connect the vacuum hose on the check valve in
the power brake vacuum booster.
(6) Install EGR Valve and vacuum transducer (Fig.
125) on the intake manifold. Install and tighten the 2
EGR valve mounting bolts to a torque of 22 N´m (200
in. lbs.).
Fig. 125 EGR Valve Attachment To Intake Manifold
Fig. 126 Vacuum Booster Input Rod Retaining Pin
Fig. 127 Retaining Pin Installed On Brake Pedal Pin
5 - 54 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

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)