II Pump Inspection & High Pressure Hose Inspection/Replacement

II. Inspection of Pump and Inspection/Replacement of High Pressure Hose





1. Remove the bolt (Figure 1) which retains both the heat shield and pump.



2. Lift the pump heat shield up into the opening above it.



3. Pull the pump up and forward to free the rubber isolation grommets from the mounting bracket. Rotate the pump 90 degrees and look at the bar code label on the driver's side of the pump.





4. Inspect the numbers printed on the pump bar code label (Figure 2):



^ If the last 6 digits of the number are from 052300 through 059262, the pump casting may be defective and the pump must be replaced. In this case proceed directly to Section III of this Service Procedure -- Replace Pump and High Pressure Hose.

^ If the last 6 digits of the number on the label are outside of the above range. the pump is acceptable. Continue with step # 5 of this Service Procedure section.

5. Return the pump to its proper position, locking the pump isolation grommets into the bracket. Reinstall the pump heat shield, install the retaining bolt and torque it to 145 in.lbs. (16 N-m).





6. Inspect the hydraulic end fitting of the high pressure hose as follows to determine if the hose requires replacement:






^ If the hose has a rubber covered end fluid as in Figure 3, the hose has already been replaced and does not require replacement again. Skip to, step # 20 of this Service Procedure section.

^ If the hose has a crimped end fitting as in Figure 4, continue with step # 7 of this Service Procedure section.








Note:
For the following steps 7 through 16, refer to Figure 5:

7. Clean the connecting points for the high pressure hose. Use Mopar Brake Parts Cleaner (PN 4549623) or equivalent.

8. Disconnect the high pressure hose from the hydraulic assembly.

9. Cut the four tie wraps attaching the high pressure hose, low pressure hose and wiring together.

10. Disconnect the high pressure hose clip from the battery tray.

11. Disconnect the pump end of the high pressure hose from the pump and motor assembly by removing and saving the banjo bolt. Clean the banjo bolt and remove the O-ring.

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.

12. Remove the high pressure hose from the vehicle.

13. Clean the pump contact face for the high pressure hose. Use Mopar Brake Parts Cleaner (PN 4549623) or equivalent.

14. Lubricate the supplied O-rings with brake fluid and install the large O-ring on the connector block face and the small O-ring on the cleaned banjo bolt.

15. Install the new high pressure hose (parts package number C3940470), fastening the connector block end to the pump face with the banjo bolt. Torque to 10 ft.lbs. (14 N-m).





16. Route the high pressure hose along the low pressure hose to the reservoir.

Important:
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. This is necessary for proper positioning of the hose clip to the battery tray in step 18.

17. Remove the cap from the fitting on the high pressure hose and install the end of the high pressure hose to the reservoir. Torque to 145 in.lbs. (16 N-m).

18. Attach the supplied high pressure hose clip to the high and low pressure hoses and attach the clip to the battery tray. 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.





19. Install the 4 supplied tie wraps around the hose assembly and wiring harness (Figure 6).



20. Reinstall the air cleaner assembly and fresh air intake duct.

21. Reconnect the battery ground.

22. Turn the ignition switch to the ON position to start the brake booster pump. Apply the brake pedal several times to distribute the fluid.





23. 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.

24. Start the vehicle and evaluate the brakes for proper function.

No other service action is necessary for these vehicles.