Caravan AWD V6-201 3.3L (1991)
9.
Disconnect the pump end of the high pressure hose from the pump and motor assembly by removing and saving the banjo bolt.
Caution:
do not disturb the pump end of the low pressure hose. After removing the connector block, the low pressure hose is only retained by the
internal O-ring seal.
10.
Remove the high pressure hose from the vehicle.
11.
Clean the pump contact face for the high pressure hose. Use Mopar Brake Parts Cleaner (PN 4549623) or equivalent.
12.
Lubricate the supplied O-Rings with brake fluid and install the large O-Ring on the connector block face of the supplied high pressure hose and the
small Oring on the cleaned banjo bolt.
13.
Install the replacement high pressure hose connector block end to the pump face with the banjo bolt. Tighten to 10 ft.lbs (14 N-m) torque.
14.
Route the high pressure hose along the low pressure hose to the hydraulic assembly.
Important:
on AS-Body vehicles, the high pressure hose must be routed along the left (driver's) side of the low pressure hose by the battery tray, and over
the low pressure hose to the hydraulic assembly (Figure 6). This is necessary for proper positioning of the hose clip to the battery tray in step
16.
15.
Remove the cap from the fitting on the supplied high pressure hose and install the end of the high pressure hose to the hydraulic assembly. Tighten
to 145 in.lbs. (16 N-m) torque.
16.
Install the 3 (AC/AY-Body) or 4 (AS-Body) supplied tie straps around the hose assembly and wiring harness as shown in Figure 4 (AC/AY) or
Figure 5 (AS-Body.
^
AS-Body -- Also install the supplied hose clip to the high and low pressure hoses and attach it to the battery tray (Figure 6). Position the low
pressure hose in the smaller loop of the clip and the high pressure hose in the larger loop for proper orientation of the clip.
17.
AC/AY-Body -- Reinstall the transmission tuning weight.
18.
Reinstall the fresh air intake duct.
^
AS-Body -- Also install the air cleaner assembly.
19.
Reconnect the battery ground.
20.
Turn the ignition switch to the ON position to start the brake booster pump. Apply the brake pedal several times to distribute the fluid.
21.
Check the master cylinder reservoir fluid level by performing the following procedure:
^
Turn the ignition off and pump the brake pedal 40 to 50 times, until the pedal is hard. The fluid level should be at the top of the inlet screen.
Add brake fluid as necessary using new Mopar brake fluid or an equivalent with SAE 1703 and DOT 3 ratings.
^
Start the vehicle and evaluate the brakes for proper function.
B. ABS High Pressure Hose Replacement -- BB-Body
1.
Pump the brake system pressure down by turning the ignition off and applying the brake pedal approximately 45-50 times, until the pedal becomes
firm.
2.
With the ignition still off, disconnect the battery ground.
3.
Remove the fresh air intake duct from the vehicle.
4.
Clean the connecting points for the high pressure hose (Figure 7). Use Mopar Brake Parts Cleaner (PN 4549623) or equivalent.
