Removal - Rhd; Installation; Installation - Lhd With Abs; Installation - Lhd Without Abs - Chrysler PT Cruiser Service & Repair Manual

PT
MASTER CYLINDER (Continued)
(10) Slide the master cylinder straight out of the
power brake booster.
(11) To remove the proportioning valves, unthread
each from the master cylinder.

REMOVAL - RHD

NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING)(Refer to 5 - BRAKES - CAUTION).
CAUTION: The vacuum in the power brake booster
must be pumped down before removing the master
cylinder to prevent the booster from sucking in any
contamination. This can be done by pumping the
brake pedal while the engine is not running until a
firm brake pedal is achieved.
(1) With the engine not running, pump the brake
pedal 4-5 strokes until the pedal feel is firm.
(2) Unclip the air cleaner cover (two clips) and
move the cover aside.
(3) Remove the air cleaner housing by pulling
straight up.
(4) Disconnect the negative (ground) cable from
the battery and isolate the cable.
(5) Remove the brake booster vacuum supply hose
from the booster and position it out of the way.
(6) Disconnect wiring harness connector from
brake fluid level switch in the brake fluid reservoir.
(7) Clean the area around where the master cylin-
der attaches to the power brake booster using a suit-
able brake cleaner such as Mopar
Cleaner or equivalent.
(8) Remove the two nuts attaching the master cyl-
inder to the power brake booster.
(9) Slide the master cylinder straight out of the
power brake booster.

INSTALLATION

INSTALLATION - LHD WITH ABS

NOTE: The master cylinder must be bled before
installing it on the vehicle.
(1) Bleed the master cylinder before installing it
on the vehicle. (Refer to 5 - BRAKES/HYDRAULIC/
MECHANICAL/MASTER CYLINDER - STANDARD
PROCEDURE)
(2) Wipe the face of the power brake booster clean
where the master cylinder seal comes in contact
when it's installed. Do not get any cleaner or debris
inside the booster.
(3) Position the master cylinder on the studs of the
power brake booster, aligning the push rod of the
power brake booster with master cylinder piston
push rod. Carefully push the master cylinder onto
the studs until it contacts the face of the booster.
(4) Install the two master cylinder mounting nuts
and tighten each to a torque of 18 N·m (160 in. lbs.).
(5) Connect the two brake tubes to the master cyl-
inder primary and secondary ports (Fig. 73). Tighten
all tube nuts to a torque of 17 N·m (145 in. lbs.).
(6) Connect the brake fluid level switch wiring
connector.
(7) Install the power distribution center.
(8) Connect the negative (ground) cable on the bat-
tery.
(9) Install the air cleaner housing.
(10) Reinstall the air cleaner cover.
(11) Fill the master cylinder reservoir to the
proper level. (Refer to 5 - BRAKES/HYDRAULIC/
MECHANICAL/FLUID - STANDARD PROCEDURE)
WARNING: Be certain a firm brake pedal is
achieved prior to attempting to operate the vehicle.
If a firm brake pedal cannot be achieved, bleed the
brake hydraulic system and check for leaks. (Refer
to 5 - BRAKES - STANDARD PROCEDURE)
(12) Road test the vehicle to ensure proper opera-
tion of the brakes.

INSTALLATION - LHD WITHOUT ABS

(1) If removed, install the proportioning valves in
their master cylinder ports. The valves are identical,
so they can be installed in either master cylinder
Brake Parts
port going to the rear brakes. Make sure the O-rings
on the proportioning valves are new.
NOTE: The master cylinder must be bled before
installing it on the vehicle.
(2) Bleed the master cylinder. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/MASTER
CYLINDER - STANDARD PROCEDURE)
(3) Wipe the face of the power brake booster clean
where the master cylinder seal comes in contact
when it's installed. Do not get any cleaner or debris
inside the booster.
(4) Position the master cylinder on the studs of the
power brake booster, aligning the push rod of the
power brake booster with master cylinder piston
push rod. Carefully push the master cylinder onto
the studs until it contacts the face of the booster.
(5) Install the two master cylinder mounting nuts
and tighten each to a torque of 18 N·m (160 in. lbs.).
(6) Connect the four brake tubes to the master cyl-
inder and proportioning valve ports (Fig. 75). Tighten
all tube nuts to a torque of 17 N·m (145 in. lbs.).
(7) Connect the brake fluid level switch wiring
connector.
BRAKES - BASE 5 - 41