Caravan AWD V6-201 3.3L (1991)
Brake Master Cylinder: Service and Repair
Hydraulic Assembly Replacement
1. Depressurize hydraulic accumulator as outlined under "Hydraulic Assembly/Service and Repair." See: Brake Fluid Accumulator/Service and
Repair/Depressurizing Hydraulic Accumulator
WARNING:Failure to de-pressurize the hydraulic accumulator, may result in personal injury, or damage to painted surfaces.
2. Remove fresh air intake and air cleaner assembly from engine.
3. Remove windshield washer fluid reservoir, then disconnect electrical connectors from hydraulic assembly.
4. Drain as much fluid from hydraulic reservoir as possible.
5. Disconnect pump high pressure line from hydraulic unit.
6. Disconnect pump return hose from steel tube, then cap the end of the steel tube.
7. Disconnect all brakes tubes from hydraulic assembly.
8. Remove retainer clip from brake pedal pin.
9. Remove four hydraulic mounting unit nuts, then the hydraulic unit.
10. Reverse procedure to install, noting the following:
a. Torque mounting bolts to 250 inch lbs.
b. Lubricate bearing surface of pedal pin with lubriplate.
c. Install new retainer clip on pedal pin.
d. Torque brake tubes to hydraulic unit to 30 ft. lbs.
e. Torque return hose clamp to 10 inch lbs.
f.
Torque high pressure hose to 145 inch lbs.
g. Bleed brake system.
