Chrysler 1998 Voyager Service Manual page 184

5 - 102 BRAKES
REMOVAL AND INSTALLATION (Continued)
Fig. 23 HCU Mounting Bolts
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.
Fig. 24 Brake Tube Routing Clips
(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.
NS