Installation - Rhd; Proportioning Valve Description - Chrysler PT Cruiser Service & Repair Manual

PT
POWER BRAKE BOOSTER (Continued)
(5) Remove and replace the brake lamp switch
with a NEW switch. Discard the original brake lamp
switch. (Refer to 8 - ELECTRICAL/LAMPS/LIGHT-
ING - EXTERIOR/BRAKE
REMOVAL) (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/BRAKE LAMP SWITCH -
INSTALLATION)
(6) Install the knee blocker.
(7) Install the silencer pad below the knee blocker.
(8) Connect all previously removed vacuum hoses
to the vacuum check valve (Fig. 86).
(9) If the vehicle is equipped with ABS, install the
ICU mounting bracket on the frame rail using its
three bolts (Fig. 85). Tighten the nuts to a torque of
23 N·m (200 in. lbs.).
(10) If the vehicle is equipped with ABS, reinstall
the ICU. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/ICU (INTEGRATED CONTROL UNIT) -
INSTALLATION)
(11) Install the master cylinder. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/MASTER
CYLINDER - INSTALLATION)
(12) Install the power distribution center.
(13) Connect the negative (ground) cable on the
battery.
(14) Install the air cleaner housing.
(15) Reinstall the air cleaner cover and hose to
throttle body.
(16) Bleed the base brake system. (Refer to 5 -
BRAKES - STANDARD PROCEDURE)
(17) Road test the vehicle to ensure proper opera-
tion of the brakes.

INSTALLATION - RHD

(1) Install the brake booster on the dash panel
using the reverse of how it was removed. Be certain
dash seal is installed on booster studs prior to instal-
lation.
(2) Under the instrument panel, install the four
power brake booster mounting nuts. Tighten the nuts
to a torque of 34 N·m (25 ft. lbs.).
(3) Using Mopar
coat the surface of the brake pedal pin where it con-
tacts the brake booster input rod.
CAUTION: Use only a new brake booster input rod-
to-brake pedal retaining clip to ensure proper
retainment.
(4) Connect the power brake booster input rod-to-
brake pedal pin. Install a new retaining clip. Do not
use the old clip.
LAMP SWITCH
Lubriplate, or an equivalent,
CAUTION: Do not reuse the original brake lamp
switch. The switch can only be adjusted once. That
is during initial installation of the switch. If the
- switch is not adjusted properly or has been
removed for some service, a new switch must be
installed and adjusted.
(5) Remove and replace the brake lamp switch
with a NEW switch. Discard the original brake lamp
switch. (Refer to 8 - ELECTRICAL/LAMPS/LIGHT-
ING - EXTERIOR/BRAKE
REMOVAL) (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/BRAKE LAMP SWITCH -
INSTALLATION)
(6) Install the knee blocker.
(7) Install the silencer pad below the knee blocker.
(8) Install the master cylinder on the vehicle.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
MASTER CYLINDER - INSTALLATION)
(9) Remove the caps and connect refrigerant lines.
Be certain the sealing O-rings are well lubricated
with PAG oil and free of tears. Torque the retaining
fastener to 40 in. lbs.
(10) Using a R-134a refrigerant recovery machine,
evacuate and charge the refrigerant system. (Refer to
24 - HEATING & AIR CONDITIONING - STAN-
DARD PROCEDURE)
(11) Connect the negative (ground) cable on the
battery.
(12) Install the air cleaner housing.
(13) Reinstall the air cleaner cover and hose to
throttle body.
WARNING: Be certain a firm brake pedal is
achieved prior to attempting to operate the vehicle.
(14) Road test the vehicle to ensure proper opera-
tion of the brakes.
PROPORTIONING VALVE
DESCRIPTION
NOTE: Only vehicles without antilock brakes have
proportioning valves. Vehicles with antilock brakes
have Electronic
(EVBP) that is built into the integrated control unit.
On the non-antilock master cylinder, two screw-in
proportioning valves are screwed directly into the
rear brake outlet ports (Fig. 94). The chassis brake
tubes leading to the rear brakes attach to the outlets
of the proportioning valves. One proportioning valve
controls each rear brake.
BRAKES - BASE
LAMP SWITCH
Variable Brake Proportioning
5 - 49
-