ANTI-LOCK BRAKE SYSTEM

General Information
The Teves Mark IV-g Anti-lock Brake System (ABS) was an option on the 199 !hrysler Minivan mo"els# Beginning in 199$% these same mo"els are e&'ippe" with the Teves Mark () ABS system# Both o* these ABS systems operate in +asically the same manner% however% they may 'se some "i**erent components# ,hen conventional +rakes are applie" in an emergency stop or on ice% one or more wheels may lock# This may res'lt in loss o* steering control an" vehicle sta+ility# The p'rpose o* the Anti-lock Brake System (ABS) is to prevent lock 'p 'n"er heavy +raking con"itions# This system o**ers the "river increase" sa*ety an" control "'ring +raking# Anti-lock +raking operates only at spee"s a+ove - mph (. km/h)# 0n"er normal +raking con"itions% the ABS *'nctions the same as a stan"ar" +rake system with a "iagonally split master cylin"er an" conventional vac''m assist# I* wheel locking ten"ency is "etecte" "'ring application% the system will enter anti-lock mo"e# 1'ring anti-lock mo"e% hy"ra'lic press're in the *o'r wheel circ'its is mo"'late" to prevent any wheel *rom locking# 2ach wheel circ'it is "esigne" with a set o* electrical valves an" hy"ra'lic line to provi"e mo"'lation% altho'gh *or vehicle sta+ility% +oth rear wheel valves receive the same electrical signal# The system can +'il" or re"'ce press're at each wheel% "epen"ing on signals generate" +y the ,heel Spee" Sensors (,SS) at each wheel an" receive" at the !ontroller Anti-lock Brake (!AB)#

PRECAUTIONS
3ail're to o+serve the *ollowing preca'tions may res'lt in system "amage4

Before performing ele tri ar !el"ing on t#e $e#i le% "i& onne t t#e ontrol mo"'le an" t#e #("ra'li 'nit onne tor&) *#en performing painting !or+ on t#e $e#i le% "o not e,po&e t#e ontrol mo"'le to temperat're& in e, e&& of -./01 2./0C3 for longer t#an 4 #o'r&) T#e &(&tem ma( 5e e,po&e" to temperat're& 'p to 46601 27/0C3 for le&& t#an -/ min'te&) Ne$er "i& onne t or onne t t#e ontrol mo"'le or #("ra'li mo"'lator onne tor& !it# t#e ignition &!it # ON) Ne$er "i&a&&em5le an( omponent of t#e Anti-Lo + Bra+e S(&tem 2ABS3 !#i # i& "e&ignate" 'n&er$i ea5le8 t#e omponent m'&t 5e repla e" a& an a&&em5l() *#en filling t#e ma&ter (lin"er% al!a(& '&e 5ra+e fl'i" !#i # meet& 9OT-: &pe ifi ation&8 petrole'm-5a&e" fl'i" !ill "e&tro( t#e r'55er part&) *or+ing on ABS &(&tem re;'ire& e,treme amo'nt of me #ani al a5ilit(% training an" &pe ial tool&) If (o' are not familiar #a$e (o'r $e#i le repaire" 5( a ertifie" me #ani or refer to a more a"$an e" p'5li ation on t#i& &'5<e t)

9iagno&i& an" Te&ting

3or the proper "iagnostic proce"'re *or either the entire ABS system or a single component o* the system% a scan tool (15B or e&'ivalent) is necessary# Beca'se o* the comple6ity o* the ABS system an" the importance o* correct system *'nctioning% it is a goo" i"ea to have a &'ali*ie" a'tomotive mechanic test the system i* any pro+lems have +een "etecte"# The sel*-"iagnostic ABS start 'p cycle +egins when the ignition switch is t'rne" to the ONposition# An electrical check is complete" on the ABS components% s'ch as the wheel spee" sensor contin'ity an" other relay contin'ity# 1'ring this check the am+er anti-lock light is t'rne" on *or appro6imately 1-( secon"s# 3'rther *'nctional testing is accomplishe" once the vehicle is set in motion#

T#e &olenoi" $al$e& an" t#e p'mp=motor are a ti$ate" 5riefl( to $erif( f'n tion T#e $oltage o'tp't from t#e !#eel &pee" &en&or& i& $erifie" to 5e !it#in t#e orre t operating range

I* the vehicle is not set in motion within - min'tes *rom the time the ignition switch is set in the ONposition% the solenoi" test is +ypasse"% +'t the p'mp/motor is activate" +rie*ly to veri*y that it is operating correctly# 3or the Teves Mark IV-g system *a'lt co"es are kept in a non-volatile memory 'ntil either erase" +y the 15B or erase" a'tomatically a*ter .) ignition cycles (key ON-OFFcycles)# The only *a'lt that will not +e erase" a*ter the .) ignition cycles is the !AB *a'lt# 7n the Teves Mark () system% 1T!s are kept in the controller8s memory 'ntil erase" with the 15B scan tool% or they are erase" a'tomatically a*ter -%.)) miles or (.. key cycles which ever occ'rs *irst# A !AB *a'lt can only +e erase" +y the 15B scan tool# More than one *a'lt can +e store" at a time# The n'm+er o* key cycles since the most recent *a'lt was store" is also "isplaye"# Most *'nctions o* the !AB an" ABS system can +e accesse" +y the 15B scan tool *or testing an" "iagnostic p'rposes# To rea" the 1iagnostic Tro'+le !o"es (1T!8s) per*orm the *ollowing4 -) In&pe t t#e ABS omponent& an" onne tor& for "amage an"=or proper onne tion&) Keep in min" t#at t#e 5ra+e lig#t ir 'it al&o pro$i"e& an inp't to to t#e ABS &(&tem) If t#e 5ra+e lig#t& "o not !or+% t#e( m'&t 5e fi,e" 5efore pro ee"ing) Conne t a 9RB or e;'i$alent & an tool to t#e 9ata Lin+ Conne tor 2lo ate" 'n"er t#e "ri$er>& &i"e in&tr'ment panel3) A & an tool m'&t 5e '&e" to a e&& t#e&e o"e&) T'rn t#e ignition to t#e ONpo&ition) *ti# t#e & an tool% &ele t ?ABS?) U&e t#e & an tool to &ele t ?Inp't&=O'tp't&?% an" rea" t#e 5ra+e &!it # &tat'&) *#ile pre&&ing on t#e 5ra+e pe"al% #e + t#e & an tool "i&pla() Sele t ?Rea" 9TC? an" re or" an( tro'5le o"e& !#i # ma( appear) Sometime&% t#e a'&e of one tro'5le o"e ma( trigger a""itional o"e& to 5e &et) If more t#an one

4)

:) -)

WARNING

1o not remove the spee" sensor with pliers *or any reason# I* the spee" sensor has sei9e"% "'e to corrosion% remove it with a small mallet an" p'nch# :ightly tap the e"ge o* the sensor ear% rocking the sensor *rom si"e to si"e 'ntil it is *ree# @) .) Remo$e t#e &pee" &en&or a5le grommet& from t#e retaining 5ra +et) Remo$e t#e !#eel &pee" &en&or from t#e $e#i le)

To install: 7) In&tall t#e &pee" &en&or #ea" into t#e &teering +n' +le) In&tall t#e mo'nting & re! an" tor;'e to -6/ in # l5&) 2-4 Nm3)

-6) In&pe t t#e air gap 5et!een t#e fa e of t#e !#eel &pee" &en&or an" t#e top &'rfa e of t#e tone !#eel) T#e air gap m'&t 5e le&& t#an t#e ma,im'm allo!a5le toleran e of 6)6A@ in # 2-)4mm3) Correct system operation depends on the wheel speed sensor cables being installed properly. Be sure the sensor cables are installed in the retainers. Failure to do this could result in cable over extension and or contact with moving parts. This could result in an open circuit and or !alse sensor readings. --) In&tall t#e &pee" &en&or !iring grommet& into t#e interme"iate retaining 5ra +et on t#e &tr't a&&em5l() Be &'re t#e &en&or a5le i& ro'te" orre tl( to t#e &tr't a&&em5l( on t#e rear!ar" &i"e of t#e &ta5iliBer 5ar lin+) -4) In&tall t#e 4 mo'nting 5olt& t#at atta # t#e #annel 5ra +et to t#e $e#i le frame) Tor;'e t#e 4 5olt& to 7/ in # l5&) 2-- Nm3) -:) In&tall t#e #annel 5ra +et an" grommet retainer onto t#e $e#i le frame rail) Be aref'l not to pin # t#e &pee" &en&or a5le 'n"er t#e #annel 5ra +et) -A) Conne t t#e !#eel &pee" &en&or onne tor to t#e $e#i le !iring #arne&& onne tor) Be &'re to &e 'rel( lat # t#e onne tor lo +ing ta5 an" &eat t#e onne tor properl() -/) In&ert t#e &en&or a5le an" a5le grommet into t#e #ole in t#e &tr't to!er) -C) In&tall t#e front !#eel an" l'g n't&) Tig#ten t#e !#eel l'g n't& in a &tar pattern &e;'en e an" tor;'e t#e n't& to #alf &pe ifi ation) T#en repeat t#e l'g n't tor;'ing &e;'en e to f'll &pe ifie" tor;'e of 7/ ft) l5&) 2-47 Nm3) -@) Lo!er t#e $e#i le) Re onne t t#e negati$e 5atter( a5le) -.) Roa" te&t t#e $e#i le to #e + t#e operation of t#e ABS an" 5a&e 5ra+e &(&tem&)

Rear *#eel Sen&or

5emove the grommet in the *loor pan to access the spee" sensor ca+le connector -) 4) :) 9i& onne t t#e negati$e 5atter( a5le) Caref'll( rai&e an" &afel( &'pport t#e $e#i le) Remo$e t#e rear !#eel) Remo$e t#e &pee" &en&or a5le grommet% t#en t#e !iring #arne&& t#ro'g# t#e #ole in t#e $e#i le floor pan) 9o NOT p'll on t#e &pee" &en&or !iring !#en remo$ing t#e grommet from t#e 'n"er5o"() 9i& onne t t#e &pee" &en&or !iring onne tor from t#e $e#i le !iring #arne&&) Be aref'l not to "amage t#e pin& of t#e !iring onne tor&) Al&o in&pe t t#e onne tor& for an( &ign& of pre$io'& "amage) Remo$e t#e &pee" &en&or !iring from t#e rear 5ra+e fle, #o&e ro'ting lip&) Be aref'l to NOT "amage t#e ro'ting lip& on t#e rear 5ra+e fle, #o&e) T#e ro'ting lip& are mol"e" to t#e 5ra+e #o&e& an" if t#e( are "amage"% t#e 5ra+e fle, #o&e& !ill re;'ire repla ement) If remo$ing t#e rig#t &i"e rear &pee" &en&or% remo$e t#e &pee" &en&or a5le grommet from t#e a,le flange% 5ra+e t'5e lip an" ro'ting lip from t#e tra + 5ar 5ra +et on t#e a,le) Remo$e t#e 4 rear &pee" &en&or a5le=5ra+e t'5e ro'ting lip& an" t#en 'n lip t#e &pee" &en&or a5le from t#e ro'ting lip& on t#e rear 5ra+e t'5e) Remo$e t#e &pee" &en&or #ea" mo'nting 5olt from t#e rear 5earing) Remo$e t#e !#eel &pee" &en&or #ea" from t#e rear 5earing a&&em5l()

A)

/)

C)

@) .)

WARNING
1o not remove the wheel spee" sensor with pliers *or any reason# I* the spee" sensor has sei9e"% "'e to corrosion% remove it with a hammer an" p'nch# :ightly tap the e"ge o* the sensor ear% rocking the sensor *rom si"e to si"e 'ntil it is *ree# 7) Remo$e t#e !#eel &pee" &en&or from t#e $e#i le)

To install: -6) In&tall t#e !#eel &pee" &en&or #ea" into t#e rear !#eel 5earing a&&em5l() Be &'re t#e pla&ti % anti-rotation pin i& f'll( &eate" in !#eel 5earing flange 5efore in&talling t#e mo'nting 5olt) In&tall t#e mo'nting 5olt an" tor;'e to -6/ in # l5&) 2-4 Nm3)

--) In&pe t t#e air gap 5et!een t#e fa e of t#e !#eel &pee" &en&or an" t#e top &'rfa e of t#e tone !#eel) T#e air gap m'&t 5e le&& t#an t#e ma,im'm allo!a5le toleran e of 6)6A@ in # 2-)4mm3) -4) In&tall t#e 4 ro'ting 5ra +et& t#at &e 're t#e &pee" &en&or a5le an" 5ra+e t'5e to t#e rear a,le) T#e &pee" &en&or a5le m'&t 5e ro'te" 'n"erneat# t#e 5ra+e t'5e) Be aref'l not to "amage t#e 5ra+e #o&e ro'ting lip&) -:) In&tall t#e &pee" &en&or a5le into t#e rear 5ra+e fle, #o&e ro'ting lip&) -A) If in&talling t#e rig#t rear &pee" &en&or a5le% in&tall t#e a5le grommet onto t#e rear a,le 5ra+e fle, #o&e 5ra +et)

WARNING
The le*t an" right rear wheel spee" sensor connectors are keye" "i**erently# There*ore% when connecting a spee" sensor ca+le to a vehicle wiring harness% "o ;7T *orce the connectors together% or "amage to the connectors will res'lt# -/) Conne t t#e &pee" &en&or !iring onne tor to t#e $e#i le !iring #arne&& an" in&tall t#e &en&or a5le grommet 5a + into t#e !iring a e&& #ole on t#e $e#i le 'n"er5o"() Be &'re t#e &pee" &en&or onne tor i& f'll( &eate" an" lo +e" into t#e $e#i le !iring #arne&&) Be &'re t#e &pee" &en&or a5le grommet i& f'll( &eate" into t#e $e#i le 'n"er5o"( !iring a e&& #ole) -C) In&tall t#e !#eel an" l'g n't&) Tig#ten t#e !#eel l'g n't& in a &tar pattern &e;'en e an" tor;'e t#e n't& to #alf &pe ifi ation) T#en repeat t#e l'g n't tig#tening &e;'en e to f'll &pe ifie" tor;'e of 7/ ft) l5&) 2-47 Nm3) -@) Lo!er t#e $e#i le to t#e gro'n") -.) Re onne t t#e negati$e 5atter( a5le) Roa" te&t t#e $e#i le an" #e + for proper 5a&e an" ABS 5ra+ing &(&tem operation)

TESTING
-) 4) :) A) /) C) In&pe t t#e &en&or an" it& onne tor) If t#e &en&or loo+& "amage" or onne tor loo+& "i&engage"% repair it a& ne e&&ar() *it# t#e ignition +e( t'rne" O11% "i&engage t#e !#eel &pee" &en&or onne tor) In&pe t t#e on"ition of t#e terminal& an" repair a& ne e&&ar() U&ing an o#mmeter% mea&'re t#e re&i&tan e 5et!een t#e !#eel &pee" &en&or onne tor terminal& on t#e &en&or &i"e) T#e re&i&tan e &#o'l" mea&'re 766--:66 o#m&) If t#e re&i&tan e mea&'re& o't&i"e t#i& $al'e% repla e t#e !#eel &pee" &en&or) T#en% mea&'re t#e re&i&tan e 5et!een eit#er one of t#e !#eel &pee" &en&or pin& an" gro'n" on t#e &en&or &i"e) If t#e re&i&tan e mea&'re& 5elo! -/+ o#m&% repla e t#e !#eel &pee" &en&or)

Controller Anti-lo + Bra+e& 2CAB3

REMODAL E INSTALLATION
-77C De#i le&
/) Atta # t#e C6-!a( onne tor to t#e CAB 5( #an" a& far a& po&&i5le% t#en '&e t#e CAB onne tor retaining 5olt to f'll( &eat t#e !iring #arne&& onne tor into t#e CAB) Tig#ten t#e C6-!a( onne tor retaining 5olt an" tig#ten to :/ in # l5&) 2A Nm3) Conne t t#e negati$e 5atter( a5le)

C) @)

-77@-77 De#i le&

7n 199$-99 vehicles% the !AB (integrate" with the <y"ra'lic !ontrol 0nit% or <!0) is locate" on the *ront s'spension cra"le

7nce the <!0 is remove"% the !AB can +e remove"

The !AB can +e separate" *rom the <!0 +y removing the = mo'nting screws The C"B is mounted to the bottom o! the #ydraulic Control $nit %#C$&. -) 4) 9i& onne t t#e negati$e 5atter( a5le) U&ing a 5ra+e pe"al "epre&&or% mo$e an" lo + t#e 5ra+e pe"al to a po&ition pa&t it& fir&t - in # of tra$el) T#i& !ill pre$ent 5ra+e fl'i" from "raining o't of t#e ma&ter (lin"er !#en t#e 5ra+e t'5e& are remo$e" from t#e proportioning $al$e) Rai&e an" &afel( &'pport t#e $e#i le &e 'rel( on <a +&tan"&) 9i&engage t#e 4/-!a( !iring #arne&& onne tor from t#e CAB 5( gra&ping t#e lo + on t#e onne tor an" p'lling it o't from t#e onne tor a& far a& it !ill go) T#i& !ill remo$e t#e onne tor o't from t#e CAB &o +et)

:) A)

WARNING
1o not apply a 1( volt power so'rce to any terminals o* the (.-way connector when it is "isengage"# /) To pre$ent po&&i5le #("ra'li &(&tem ontamination% t#oro'g#l( lean t#e FCU an" 5ra+e t'5e&) U&e MOPARG Bra+e Part& Cleaner% or an e;'i$alent &ol$ent) C) La5el an" "i& onne t t#e #a&&i& 5ra+e t'5e& from t#e inlet an" o'tlet port& of t#e FCU) @) Remo$e t#e : 5olt& atta #ing t#e FCU mo'nting 5ra +et to t#e front &'&pen&ion ro&&mem5er) .) Remo$e t#e FCU an" t#e mo'nting 5ra +et a& a 'nit from t#e $e#i le) 7) Remo$e t#e : 5olt& mo'nting t#e FCU to t#e mo'nting 5ra +et) Separate t#e FCU from t#e mo'nting 5ra +et) -6) Unpl'g t#e p'mp motor !iring #arne&& from t#e CAB) --) Loo&en t#e A mo'nting 5olt&% t#en &eparate t#e CAB from t#e $al$e 5lo + of t#e FCU)

Proportioning Dal$e
REMODAL E INSTALLATION

>roportioning valve "etail *or ABS-e&'ippe" vehicles

-)

U&ing a 5ra+e pe"al "epre&&or% mo$e an" lo + t#e 5ra+e pe"al to a po&ition pa&t it& fir&t - in # of tra$el) T#i& !ill pre$ent 5ra+e fl'i" from "raining o't of t#e ma&ter (lin"er !#en t#e 5ra+e t'5e& are remo$e" from t#e proportioning $al$e) Rai&e an" &afel( &'pport t#e $e#i le &e 'rel( on <a +&tan"&)

4)

To prevent possible hydraulic system contamination' thoroughly clean the proportioning valve and bra(e tubes. $se )O*"+, Bra(e *arts Cleaner' or an e-uivalent solvent. :) A) Remo$e t#e A 5ra+e line& from t#e inlet an" o'tlet port& of t#e proportioning $al$e) Remo$e t#e 5olt& &e 'ring t#e proportioning $al$e 5ra +et to t#e $e#i le frame rail) Remo$e t#e proportioning $al$e a&&em5l( from t#e $e#i le)

To install: /) C) @) .) 7) Pla e t#e proportioning $al$e a&&em5l( into po&ition on t#e frame rail) In&tall t#e mo'nting 5olt& an" tig#ten to -6 ft) l5&) 2-A Nm3) In&tall t#e #a&&i& 5ra+e line& into t#e proportioning $al$e a&&em5l() Tig#ten t#e 5ra+e line fitting& to -4 ft) l5&) 2-C Nm3) Blee" t#e 5ra+e &(&tem) Lo!er t#e $e#i le) Caref'll( roa" te&t t#e $e#i le to $erif( proper 5ra+e &(&tem operation)

Tone 2E, iter3 Ring

REMODAL E INSTALLATION
Rear *#eel 2All *#eel 9ri$e Onl(3 an" 1ront *#eel Tone Ring&
The *ront ABS tone ring an" rear ABS tone ring (All ,heel 1rive only) are integral components o* the hal*sha*t assem+lies an" there*ore% cannot +e service" separately# I* any o* these tone rings re&'ire service% the hal*sha*t assem+ly m'st +e replace"# <owever% the rear ABS tone ring on *ront wheel "rive vehicles can +e service" -) Tool C-AC7:% or e;'i$alent% remo$e t#e tone !#eel from t#e 5a + of t#e #'5=5earing a&&em5l()

To install: A) Po&ition t#e #'5=5earing a&&em5l( in an ar5or pre&& &'pporte" 5( Re ei$er Spe ial Tool C6C4A-:) Po&ition 9ri$er Spe ial Tool C76.-- !it# t#e 'n"er 't &i"e fa ing 'p on top of t#e tone !#eel) Pre&& t#e tone !#eel onto t#e #'5=5earing a&&em5l( 'ntil it fit& fl'&# !it# t#e en" of t#e #'5 &#aft) In&tall t#e #'5=5earing a&&em5l( onto t#e $e#i le) In&tall t#e rear !#eel &pee" &en&or onto t#e rear #'5=5earing flange) In&pe t t#e air gap 5et!een t#e fa e of t#e !#eel &pee" &en&or an" t#e top &'rfa e of t#e tone !#eel) T#e air gap m'&t 5e le&& t#an t#e ma,im'm allo!a5le toleran e of 6)6A@ in # 2-)4mm3) In&tall t#e 5ra+e "r'm=rotor)

/) C) @) .)

7)

-6) In&tall rear !#eel2&3) --) A"<'&t t#e rear 5ra+e&)

Blee"ing t#e ABS S(&tem

The +lee"ing proce"'re is a (-step process% one o* which will re&'ire 'se o* the 15B scan tool or its e&'ivalent# Blee" the system as *ollows4 -) 4) Lo ate t#e "iagno&ti onne tor 'n"er t#e "a&# panel to t#e left of t#e &teering ol'mn o$er) Conne t t#e 9RB & an tool to t#e onne tor) In&tall t#e orre t artri"ge for t#e Anti-Lo + Bra+e &(&tem&) C#e + to ma+e &'re t#e CAB 2Controller Antilo + Bra+e&3 "oe& not #a$e an( fa'lt o"e& &tore" in it) If it "oe&% remo$e t#em '&ing t#e 9RB & an tool)

CAUTION
Be s're to always wear sa*ety glasses when +lee"ing the +rake system# This will prevent personal in?'ry to yo'r eyes in case *l'i" s&'irts o't at high press're# :) Blee" t#e 5a&e 5ra+e &(&tem '&ing t#e non-ABS man'al 5lee"ing met#o" a& o'tline" earlier in t#i& &e tion) Be &'re to 5lee" t#e 5ra+e &(&tem in t#e orre t &e;'en e) UtiliBing t#e & an tool% go to t#e ?Blee" ABS? ro'tine) 1irml( appl( t#e 5ra+e pe"al to initiate t#e ?Blee" ABS? ( le one time) Relea&e t#e 5ra+e pe"al) U&ing t#e & an tool% go on to 5lee" t#e Anti-Lo + Bra+e S(&tem a or"ing to t#e & an tool literat're) On e 5lee"ing !it# t#e & an tool i& omplete% repeat t#e on$entional 5lee" pro e"'re for t#e 5a&e 5ra+e &(&tem)

A) /) C)