Chrysler Caravan/Voyager/Town n Country 1984-1995

Pump/Motor Assembly

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REMOVAL & INSTALLATION




CAUTION
This brake system uses a hydraulic accumulator which, when fully charged, contains brake fluid at very high pressure. Before disconnecting any hydraulic lines, hoses or fittings be certain that the accumulator pressure is completely relieved. Failure to depressurize the accumulator may result in personal injury and/or vehicle damage.

  1. Disconnect the negative battery cable.
  2.  
  3. Depressurize the brake system.
  4.  
  5. Remove the fresh air intake ducts from the engine.
  6.  
  7. On Van/wagon vehicles, loosen the low pressure hose clamp at the hydraulic unit. Remove the clip holding the high pressure line to the battery tray.
  8.  
  9. Disengage the electrical connectors running across the engine compartment in the vicinity of the pump/motor high and low pressure hoses. One of these connectors is the one for the pump/motor assembly.
  10.  
  11. Disconnect the high and low pressure hoses from the hydraulic assembly. Cap or plug the reservoir fitting.
  12.  
  13. Disengage the pump/motor electrical connector from the engine mount.
  14.  
  15. Unfasten the heat shield bolt from the front of the pump bracket. Remove the heat shield.
  16.  
  17. Lift the pump/motor assembly from the bracket and out of the vehicle.
  18.  

To install:
  1. Fit the pump motor assembly onto the bracket; install the heat shield and its retaining bolt.
  2.  
  3. Install the pump/motor electrical connector to the engine mount.
  4.  
  5. Connect the high and low pressure hose to the hydraulic assembly. Tighten the high pressure line to 12 ft. lbs. (16 Nm). Tighten the hose clamp on the low pressure hose to 10 inch lbs. (1 Nm).
  6.  
  7. Engage the electrical connectors which were removed for access.
  8.  
  9. Install the high pressure line retaining clip to the battery tray if it was removed.
  10.  
  11. Install the fresh air intake ducts.
  12.  
  13. Bleed the brake system.
  14.  

 
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