III Pump and High Pressure Hose Replacement
III. Replace Pump and High Pressure HoseIf pump replacement is required (see pump inspection, Section II step # 4 of this Service Procedure), proceed as follows.
Note:
For the following steps 1 through 6, refer to Figure 7.
1. Clean the connecting points for the high and low pressure hoses at the hydraulic assembly. Use Mopar Brake Parts Cleaner (PN 4549623) or equivalent.
2. Disconnect the high pressure hose at the hydraulic assembly.
3. Disconnect the low pressure hose at the hydraulic assembly and cap the low pressure nipple on the hydraulic assembly, to reduce the loss of brake fluid.
4. Disconnect the high pressure hose clip from the battery tray.
5. Disconnect the pump wiring connector and remove the pump and hose assembly from the engine compartment.
6. Cut the tie wraps attaching the high pressure hose, low pressure hose and wiring together.
7. Transfer the rubber isolation grommets from the front and rear of the removed pump to the new pump from parts package number C3940478.
8. Remove the banjo bolt from the pump/connector block high pressure hose and remove the high and low pressure hoses from the pump. Clean the banjo bolt and remove the O-ring.
9. Remove the O-ring from the low pressure hose fitting.
10. Lubricate the supplied low pressure hose O-ring with brake fluid and install it on the low pressure hose.
11. Install the low pressure hose to the new pump.
12. Use parts package C3940470 to replace the high pressure hose.
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 supplied high pressure hose fastening the connector block end to the pump face with the banjo bolt. Torque to 10 ft.lbs. (14 N-m).
16. Install the 4 supplied tie straps and battery tray clip around the hose assembly and wiring harness (Figure 8). 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. Install the pump and hose assembly into the vehicle. Lock the pump isolation grommets into the bracket.
Important:
Feed the hoses under the engine compartment wiring harness. Route the high pressure hose 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 the following step 22.
18. Reinstall the pump heat shield, install the retaining bolt and torque to 145 in. lbs. (16 N-m).
19. Remove the cap from the low pressure nipple at the hydraulic assembly and reconnect the low pressure hose. Torque the clamp to 10 in.lbs. (1 N-m).
20. Reconnect the pump electrical connector.
21. Connect the high pressure hose at the hydraulic assembly. Torque to 145 in.lbs. (16 N-m).
22. Attach the hose clip to the battery tray.
23. Reinstall the air cleaner assembly and fresh air intake duct.
24. Reconnect the battery ground.
25. Turn the ignition switch to the ON position to start the brake booster pump. Apply the brake pedal several times to distribute the fluid.
26. 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.
27. Start the vehicle and evaluate the brakes for proper function.
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
Inspect ABS pump and high pressure 05527181 0.3 Hour
hose
Inspect ABS pump and high pressure 05527182 0.7 Hour
hose and replace high pressure hose
Inspect ABS pump and replace pump 05527183 0.8 Hour
and high pressure hose
Add the cost of any parts or materials used (hose, pump, brake fluid) plus applicable dealer allowance to your claim.
Parts Return
Removed high pressure hoses must be returned to the Warranty Material Return Center.
Note:
See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim processing and material return instructions.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Recall Notification Form or describe the reason on a postcard and mail to:
Chrysler Corporation 415-03-18
Recall Coordination
P.O. Box 1919
Detroit, Michigan 48231-9986
Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone Service Office.