Chrysler PT Cruiser. Manual — part 447
(12) Disengage master cylinder grommet and slide
back (Fig. 63).
(13) Release master cylinder by rotating to disen-
gage from pedal bracket assembly. 1.6/2.4L 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: 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.
CAUTION: Brake fluid will damage painted surfaces.
If brake fluid is spilled on any painted surfaces,
wash it off immediately with water.
(14) Remove
master
cylinder
assembly
from
mounting position and carefully work hydraulic pipe
from out of engine compartment (Fig. 64).
INSTALLATION
(1) Install clutch master cylinder into position but
do not fasten to brake pedal bracket at this
time. (Fig. 65) Carefully route hydraulic pipe into
position as removed.
Fig. 63 Master Cylinder Mounting—RHD
1 - RESERVOIR
Fig. 64 Master Cylinder Mounting—RHD
1 - RESERVOIR
Fig. 65 Master Cylinder Mounting—RHD
1 - RESERVOIR
6 - 32
CLUTCH
PT
MASTER CYLINDER - RHD (Continued)
(2) Fasten hydraulic supply tube to retainer at left
rail (Fig. 66).
(3) Connect hydraulic supply tube to clutch slave
cylinder:
(a) 1.6L/2.4L N/A Models: Raise vehicle on
hoist. Insert tube into slave cylinder port, depress
both retaining clips to secure (Fig. 67), and verify
connection by pulling outward. Lower vehicle.
(b) 2.4L Turbo & 2.2L Diesel Models: Insert
tube into slave cylinder port, depress both retain-
ing clips to secure, and verify connection by pulling
outward.
(4) Connect clutch master cylinder supply hose to
brake master cylinder reservoir and secure with
clamp (Fig. 68).
(5) Fill clutch hydraulic release system with fluid:
(a) 1.6L/2.4L N/A Models: Fill brake master
cylinder to the top with suitable DOT3 fluid. Leave
cap off. Raise vehicle on hoist.
(b) Remove bleed port protective cap, and install
suitable size and length of clear hose to monitor
and divert fluid into suitable container.
(c) Release only the lower hydraulic tube snap
ring, pull outward on tube until it stops against
the second ring, opening up the bleed circuit and
starting the air purge and fluid fill process (Fig.
69).
(d) Lower vehicle, but only enough to gain access
to and fill the brake master cylinder.
(e) Top off brake master cylinder fluid level
while air is purged and fluid drains from bleed
port. Continue this until no air bubbles are seen
and a solid column of fluid exists.
(f) Close hydraulic bleed circuit. Insert hydraulic
pipe fully into slave cylinder and depress retaining
ring (Fig. 72). Remove drain hose.
(g) 2.4L Turbo & 2.2L Turbo Diesel Fill brake
master cylinder to the top with suitable DOT3
fluid. Leave cap off.
Fig. 66 Master Cylinder Pipe at Left Rail
1 - RETAINER
2 - MASTER CYLINDER PIPE
Fig. 67 Hydraulic Tube Retaining Clips
1 - RETAINER CLIPS
Fig. 68 Clutch Master Cylinder Supply Hose
1 - BRAKE MASTER CYLINDER RESERVOIR
2 - HOSE CLAMP
3 - CLUTCH MASTER CYLINDER SUPPLY HOSE
PT
CLUTCH
6 - 33
MASTER CYLINDER - RHD (Continued)
(h) Remove bleed port protective cap, and install
suitable size and length of clear hose to divert fluid
into suitable container.
(i) Release only the inboard hydraulic tube snap
ring (Fig. 70), pull outward on tube until it stops
against the second ring, opening up the bleed cir-
cuit and starting the fluid fill process (Fig. 71).
(j) Top off brake master cylinder fluid level while
air is purged and fluid drains from bleed port. Con-
tinue this until no air bubbles are seen and a solid
column of fluid exists.
(k) Close hydraulic bleed circuit. Insert hydrau-
lic pipe fully into slave cylinder and depress retain-
ing ring (Fig. 72). Remove drain hose.
CAUTION: Due to clutch master cylinder design and
placement, the master cylinder body traps a signif-
icant amount of air which does not purge by means
of normal methods. It is necessary to position mas-
ter cylinder body vertical, with pushrod pointing
down, for about ten seconds to purge air trapped
from end of cylinder. Failure to perform this step
upon assembly will result in inadequate system
bleeding and poor release system functionality.
(6) Verify that brake master cylinder reservoir is
full and cap is off.
(7) Remove clutch master cylinder body from dash
panel. Position master cylinder body vertically, with
pushrod pointing down, for about ten seconds to
purge air trapped from end of cylinder. Install brake
master cylinder cap.
Fig. 69 Opening Hydraulic Circuit Bleed - 1.6/2.4L
Models
1 - RETAINING RING
2 - CLEAR HOSE
3 - HYDRAULIC TUBE
Fig. 70 Releasing Inboard Retainer—Typical
1 - INBOARD RETAINER
Fig. 71 Opening Hydraulic Circuit Bleed Port
1 - CLEAR HOSE
2 - HYDRAULIC TUBE
3 - RETAINER RING
6 - 34
CLUTCH
PT
MASTER CYLINDER - RHD (Continued)
(8) Install clutch master cylinder body through
dash panel to pedal bracket assembly and rotate to
secure (Fig. 73). 1.6/2.4L models: Rotate master
cylinder clockwise (facing dash from under-
hood)
to
install.
2.2L
Turbo-Diesel
Models:
Rotate master cylinder counter-clockwise (fac-
ing dash from underhood) to install.
(9) Install and secure grommet (Fig. 73).
(10) From inside vehicle, connect clutch master
cylinder rod to clutch pedal pin. An audible “click”
should be heard. If damaged, replace nylon retainer.
(11) Install brake booster into position. Connect
push rod to brake pedal pin (Fig. 74).
(12) Install and torque brake booster-to-dash panel
nuts (Fig. 74) 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. 75).
(15) Install PDC bracket into position.
(16) Raise vehicle on hoist.
Fig. 72 Hydraulic Tube Retaining Clips
1 - RETAINER CLIPS
Fig. 73 Master Cylinder Mounting—RHD
1 - RESERVOIR
Fig. 74 Brake Booster Mounting Nuts
1 - CLIP
2 - BOOSTER MOUNTING NUTS
3 - BOOSTER MOUNTING NUTS
Fig. 75 Lower Instrument Panel Bezel
1 - INSTRUMENT PANEL
2 - INSTRUMENT PANEL STEERING COLUMN COVER
PT
CLUTCH
6 - 35
MASTER CYLINDER - RHD (Continued)
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