Installation - Chrysler PT Cruiser Service & Repair Manual

PT
MASTER CYLINDER - RHD (Continued)
(11) Remove clutch master cylinder reservoir (Fig. 54).
(12) Disengage master cylinder hydraulic pipe
from dash panel retainer (Fig. 52).
CAUTION: Use care when removing clutch master
cylinder from engine compartment. Aggressive han-
dling can result in a damaged hydraulic tube and
improper clutch release operation upon reassembly.
(13) Disengage master cylinder grommet and slide
back (Fig. 54).
(14) Release master cylinder by rotating to disen-
gage from pedal bracket assembly. 2.0L models:
Rotate master cylinder counter-clockwise (fac-
ing dash from underhood) to remove. 2.2L
Turbo Diesel Models: Rotate master cylinder
clockwise (facing dash from underhood) to
remove.
CAUTION: Brake fluid will damage painted surfaces.
If brake fluid is spilled on any painted surfaces,
wash it off immediately with water.
(15) Remove master cylinder from mounting posi-
tion and carefully work hydraulic pipe from out of
engine compartment (Fig. 54). 1.6/2.0/2.4L (Non-
Turbo)-equipped models: If master cylinder is
being replaced, it is necessary to cut hydraulic tube,
breaking system into two pieces for easy removal.
Fig. 54 Clutch Master Cylinder Removal/Installation
1 - RESERVOIR
2 - GROMMET
3 - MASTER CYLINDER

INSTALLATION

NOTE: Vehicles equipped with a 1.6/2.0/2.4L (Non-
Turbo) engine have one-piece master/slave cylinder
assemblies. If the master cylinder requires replace-
ment, the master AND slave cylinders must be
replaced with a two-piece "quick-connect" system.
If the slave cylinder requires replacement, the slave
cylinder is serviced separately.
NOTE: Replacement master cylinder assemblies
come pre-filled with fluid. No fluid service or sys-
tem bleeding should be required, unless the
hydraulic system has lost an excessive amount of
fluid and has ingested air into the master or slave
cylinder assembly.
(1) Carefully route hydraulic pipe into position as
removed and install clutch master cylinder into posi-
tion (Fig. 54). Rotate master cylinder to engage pedal
bracket assembly. 2.0L models: Rotate master cyl-
inder clockwise (facing dash from underhood)
to install. 2.2L Turbo Diesel Models: Rotate
master cylinder counter-clockwise (facing dash
from underhood) to install.
(2) Install and secure grommet (Fig. 54).
(3) Install hydraulic pipe into dash panel retainer
(Fig. 52).
(4) Install clutch master cylinder reservoir (Fig. 54).
(5) Raise vehicle.
(6) Install clutch master cylinder hydraulic pipe
into left rail retainer (Fig. 52).
(7) If master cylinder is being replaced, install ser-
vice replacement slave cylinder. If original master
cylinder is being re-used, install slave cylinder as
shown in (Fig. 50) (Fig. 51).
(8) Diesel and Turbo Models: Connect hydraulic
pipe to clutch slave cylinder (Fig. 49). An audible
"click" should be heard. Verify connection by pulling
outward on connection.
(9) Lower vehicle.
(10) Connect clutch master cylinder rod to clutch
pedal pin. An audible "click" should be heard. If dam-
aged, replace nylon retainer.
(11) Install lower instrument panel bezel (Fig. 53).
(12) Connect battery negative cable.
(13) Install air cleaner assembly (Fig. 47).
(14) Verify that reservoir is full. Top off with DOT
3 brake fluid if necessary.
(15) Actuate clutch pedal a minimum of ten times
to allow any air ingested into the system to vent to
the master cylinder reservoir.
(16) Verify proper clutch release system operation.
Excessive residual air in the system can be identified
by a spongy pedal and/or improper clutch operation.
If necessary, bleed clutch hydraulic system. (Refer to
6 - CLUTCH - STANDARD PROCEDURE)
CLUTCH 6 - 29