Chrysler PT Cruiser. Manual — part 446
(7) Install master cylinder body to dash panel.
From inside vehicle, install and torque two clutch
master cylinder-to-dash panel retaining nuts (Fig. 50)
to 15 N·m (130 in. lbs.) torque.
(8) Loosen master cylinder pushrod adjustment
screw (Fig. 51).
(9) Connect clutch master cylinder rod to clutch
pedal pin. An audible “click” should be heard. If dam-
aged, replace nylon retainer.
(10) Adjust
clutch
pedal
position.
Gently
lift
upward on clutch pedal. Tighten adjustment screw to
6 N·m (55 in. lbs.) torque.
(11) Install brake booster into position. Connect
push rod to brake pedal pin (Fig. 52).
(12) Install and torque brake booster-to-cowl panel
nuts (Fig. 52) to 34 N·m (300 in.lbs.). Install push
rod retaining clip.
(13) Replace stop lamp switch. Refer to Stop Lamp
Switch Removal and Installation.
(14) Install lower instrument panel bezel (Fig. 53).
Fig. 50 Master Cylinder Mounting Nuts
1 - MASTER CYLINDER
2 - NUTS
Fig. 51 Clutch Pedal Adjustment
1 - ADJUSTMENT SCREW
Fig. 52 Brake Booster Mounting Nuts
1 - CLIP
2 - BOOSTER MOUNTING NUTS
3 - BOOSTER MOUNTING NUTS
Fig. 53 Left Lower Instrument Panel Bezel
1 - INSTRUMENT PANEL
2 - INSTRUMENT PANEL STEERING COLUMN COVER
6 - 28
CLUTCH
PT
MASTER CYLINDER - LHD (Continued)
(15) Install PDC bracket into position.
(16) Raise vehicle on hoist.
(17) Connect battery negative cable.
(18) Install air cleaner assembly (Fig. 54).
(19) Verify that brake master cylinder reservoir is
full. Top off with DOT 3 brake fluid if necessary.
(20) Actuate clutch pedal a minimum of fifty times
to allow any air ingested into the system to vent to
the master cylinder reservoir. If residual air becomes
trapped in the system, it is necessary to bleed the
clutch hydraulic system. (Refer to 6 - CLUTCH -
STANDARD PROCEDURE)
(21) Verify proper clutch release system operation.
MASTER CYLINDER - RHD
DESCRIPTION
The clutch master cylinder mounts to the dash panel
(Fig. 55) and consists of a piston and cylinder housing,
an actuating push rod, and an interconnecting hydraulic
tube. Fluid is supplied to the clutch master cylinder via
the brake master cylinder reservoir.
OPERATION
The clutch master cylinder (Fig. 55) produces the
hydraulic pressure necessary to disengage the clutch.
When the clutch pedal is depressed, the push rod
moves the piston to produce pressure in the cylinder.
This pressure moves fluid through the system to the
slave cylinder, which in turn operates the release
lever and bearing (T350 Models Only), disengaging
the clutch. When the clutch pedal is released, pres-
sure is relieved and the return spring returns the
piston to its original position until the next pedal
actuation.
REMOVAL
(1) Remove air cleaner assembly (Fig. 56).
(2) Disconnect battery negative cable.
Fig. 54 Air Cleaner Assembly Removal/Installation—
Typical
1 - AIR CLEANER ASSEMBLY
Fig. 55 Master Cylinder Mounting—RHD
1 - RESERVOIR
Fig. 56 Air Cleaner Assembly Removal/Installation
1 - AIR CLEANER ASSEMBLY
PT
CLUTCH
6 - 29
MASTER CYLINDER - LHD (Continued)
CAUTION: Brake fluid will damage painted surfaces.
If brake fluid is spilled on any painted surfaces,
wash it off immediately with water.
(3) Remove PDC bracket and position out of way.
(4) Disconnect hydraulic supply tube at clutch
slave cylinder. To completely drain clutch master cyl-
inder and tubing, remove brake master cylinder cap.
(a) 1.6L/2.4L N/A Models: Raise vehicle on
hoist. Using suitable screwdriver, release both
hydraulic tube retaining clips (Fig. 57). Disconnect
tube and drain fluid into suitable container. Lower
vehicle.
(b) 2.4L Turbo & Diesel Models: Using suit-
able
screwdriver,
release
both
hydraulic
tube
retaining clips (Fig. 58). Disconnect tube and drain
fluid into suitable container.
(5) From inside vehicle, remove lower instrument
panel bezel (Fig. 59).
Fig. 57 Hydraulic Tube Retainer Clips - 1.6/2.4L
1 - RETAINER CLIPS
Fig. 58 Hydraulic Tube Retainer Clips - Diesel/Turbo
1 - RETAINER CLIPS
Fig. 59 Left Lower Instrument Panel Bezel
1 - INSTRUMENT PANEL
2 - INSTRUMENT PANEL STEERING COLUMN COVER
6 - 30
CLUTCH
PT
MASTER CYLINDER - RHD (Continued)
(6) Remove clip and disconnect the brake booster
input rod from the brake pedal pin (Fig. 60).
(7) Remove the brake booster mounting nuts (Fig.
60).
(8) Slide brake booster forward enough to gain
access to and remove clutch master cylinder.
(9) Disconnect
clutch
master
cylinder
pushrod
from clutch pedal. Inspect retainer bushing and
replace if damaged in any way.
(10) Disconnect clutch master cylinder supply line
from brake master cylinder reservoir (Fig. 61). Cap
off or collect reservoir fluid spillage.
(11) Remove hydraulic tube from left rail retainer
(Fig. 62).
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.
Fig. 60 Brake Booster Mounting Nuts
1 - CLIP
2 - BOOSTER MOUNTING NUTS
3 - BOOSTER MOUNTING NUTS
Fig. 61 Clutch Master Cylinder Supply Hose
1 - BRAKE MASTER CYLINDER RESERVOIR
2 - HOSE CLAMP
3 - CLUTCH MASTER CYLINDER SUPPLY HOSE
Fig. 62 Master Cylinder Pipe at Left Rail
1 - RETAINER
2 - MASTER CYLINDER PIPE
PT
CLUTCH
6 - 31
MASTER CYLINDER - RHD (Continued)
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