Chrysler neon 1997 Service Manual page 158

PL
REMOVAL AND INSTALLATION (Continued)
Fig. 22 Vacuum Seal Positioned For Installing
Master Cylinder
(15) Install the 2 master cylinder to power brake
unit mounting nuts (Fig. 14) and torque to 28 N·m
(250 in. lbs.) torque.
(16) Connect brake tubes to master cylinder pri-
mary and secondary ports (Fig. 13). Torque all tube
nuts to 17 N·m (145 in. lbs.) torque.
(17) Install the wiring harness connector on the
master cylinder reservoir brake fluid level switch
(Fig. 12).
(18) Bleed the base brakes and the ABS brakes
hydraulic systems. Refer to Bleeding Base Brake
Hydraulic System in Service Procedures of the Base
Brake Section and Antilock Brakes Hydraulic System
Bleeding Procedure in Service Procedures of the
Antilock Brake Section for the required procedures.
(19) Road test vehicle to ensure proper operation
of the base and ABS brake systems.
PROPORTIONING VALVES
The HCU does not require removal from the vehi-
cle for the replacement of the proportioning valves.
Use the proportioning valve test procedure in the
Diagnosis And Testing Section in this group of the
service manual to determine which proportioning
valve requires replacement, then replace it using pro-
cedure below.
REMOVE
(1) Disconnect the brake tube fitting from the pro-
portioning valve requiring removal from the HCU
(Fig. 23).
(2) Remove proportioning valve (Fig. 23) requiring
replacement, from the HCU.
INSTALL
(1) Wet O-ring seal on new proportioning valve
using clean fresh brake fluid.
Fig. 23 Rear Wheel Proportioning Valve Location On
(2) Install proportioning valve in HCU and hand
tighten until proportioning is fully installed and
O-ring seal is seated into HCU. Then torque propor-
tioning valve to 40 N·m (30 ft. lbs.).
(3) Install brake tube on proportioning valve.
Tighten tube nut to 17 N·m (145 in. lbs.) torque.
(4) Bleed the base brakes hydraulic system. Refer
to Bleeding Base Brake Hydraulic System in Service
Procedures of the Base Brake Section.
MASTER CYLINDER AND POWER BRAKE BOOSTER
If the Master Cylinder or the Power Booster need
to be serviced or replaced, refer to Master Cylinder
or Power Brake Booster in the Removal And Instal-
lation Section in the Base Brake Section of this ser-
vice manual.
RELAY BOX
The system relay and pump/motor relay are both
serviced together as an assembly with the relay box.
The relay box is mounted directly to the HCU.
To remove the relay box from the HCU, the HCU
requires removal from the vehicle. This is to allow
visual access of the relay box to HCU electrical con-
nection. Visual access to this connection is necessary
to be sure connection is correctly made when install-
ing relay box on the HCU.
REMOVE
(1) Disconnect negative (ground) cable from the
battery and isolate the cable.
(2) Remove the HCU from the vehicle. See
Hydraulic Control Unit in the Removal And Installa-
tion Section of the Antilock Brake System Section, in
this group of the service manual, for the required
HCU removal procedure.
(3) Unclip the 6 way wiring harness connector
(Fig. 24) from the relay box.
BRAKES
HCU
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