Chrysler PT Cruiser. Manual — part 414
(6) Bleed the remaining wheel circuits in the same
manner until all air is removed from the brake sys-
tem. Monitor the fluid level in the master cylinder
reservoir to make sure it does not go dry.
(7) Check the brake pedal travel. If pedal travel is
excessive or has not been improved, some air may
still be trapped in the system. Rebleed the brakes as
necessary.
(8) Test drive the vehicle to verify the brakes are
operating properly and pedal feel is correct.
PRESSURE BLEEDING
NOTE:
Follow
pressure
bleeder
manufacturer’s
instructions for use of pressure bleeding equip-
ment.
Following the same wheel circuit sequence as pre-
scribed for manual bleeding.
(1) Attach Adapter, Special Tool 6921, to the mas-
ter cylinder reservoir (Fig. 2).
(2) Attach Bleeder Tank, Special Tool C-3496-B, or
an equivalent, to the adapter on the master cylinder.
(3) Attach a clear plastic hose to the bleeder screw
and feed the hose into a clear jar containing enough
fresh brake fluid to submerge the end of the hose
(Fig. 1).
(4) Open the bleeder screw at least one full turn or
more to obtain a steady stream of brake fluid.
(5) After approximately 4–8 ounces of fluid have
been bled through the brake circuit and an air-free
flow is maintained in the clear plastic hose and jar,
close the bleeder screw.
(6) Repeat this procedure at all the remaining
bleeder screws.
(7) Check the brake pedal travel. If pedal travel is
excessive or has not been improved, some air may
still be trapped in the system. Rebleed the brakes as
necessary.
(8) Test drive the vehicle to verify the brakes are
operating properly and pedal feel is correct.
SPECIFICATIONS
BRAKE ACTUATION SYSTEM
ACTUATION:
Vacuum Operated Power
Brakes
Standard
Hydraulic System
Dual-Diagonally Split
BRAKE PEDAL:
Pedal Ratio - Bosch
Booster and Master
Cylinder
3.75
Pedal Ratio - Continental
Teves Booster and
Master Cylinder
3.4
POWER BRAKE BOOSTER - BOSCH:
Type
Vacuum Assist
Mounting Studs
M8 x 1.25
Diaphragm Size/Type
205 mm /Tandem
POWER BRAKE BOOSTER - CONTINENTAL
TEVES:
Type
Vacuum Assist
Mounting Studs
M8 x 1.25
Diaphragm Size/Type
200 mm /Tandem
MASTER CYLINDER ASSEMBLY - BOSCH:
Type
Compact
Body Material
Anodized Aluminum
Reservoir Material
Polypropelene
Bore and Stroke
23.82 mm x 34.0 mm
(0.937 in. x 1.34 in.)
Displacement Split
50 / 50
MASTER CYLINDER ASSEMBLY - CONTINENTAL
TEVES:
Type
Compact
Body Material
Anodized Aluminum
Reservoir Material
Polypropelene
Bore and Stroke
22.2 mm x 42.2 mm
(0.874 in. x 1.661 in.)
Displacement Split
50 / 50
Fig. 2 Special Tool 6921
1 - MASTER CYLINDER FLUID RESERVOIR
5 - 8
BRAKES - BASE
PT
BRAKES - BASE (Continued)
ACTUATION:
MASTER CYLINDER FLUID OUTLET PORTS -
BOSCH:
Tube Fitting Type
SAE 45° Inverted Flare
W/ABS - Primary Tube
Nut Thread
7/16 in.–24
W/ABS - Secondary Tube
Nut Thread
3/8 in.–24
W/O ABS - All Tube Nut
Threads
7/16 in.–24
MASTER CYLINDER FLUID OUTLET PORTS -
CONTINENTAL TEVES:
Tube Fitting Type
ISO Flare
Primary Tube Nut Thread
- All
M10 x 1
Secondary Tube Nut
Thread - All
M12 x 1
PROPORTIONING VALVE - ALL:
Material
Aluminum
Function
Fixed Pressure
Proportioning
Outlet Tube Fitting Type
SAE 45° Inverted Flare
Outlet Tube Nut Threads
3/8 in.–24
ABS HYDRAULIC CONTROL UNIT PORTS -
MK20E:
Tube Fitting Type
SAE 45° Inverted Flare
Inlet Port Threads (Both)
7/16 in.–24
Outlet Port Threads-Left
Front and Left Rear
3/8 in.–24
Outlet Port Threads-Right
Front and Right Rear
7/16 in.–24
ABS HYDRAULIC CONTROL UNIT PORTS -
MK25E:
Tube Fitting Type
ISO Flare
Inlet Port Threads (Both)
M12 x 1
Outlet Port Threads-Left
Front and Left Rear
M12 x 1
Outlet Port Threads-Right
Front and Right Rear
M10 x 1
BRAKE FASTENER TORQUE
DESCRIPTION
N·m
Ft.
Lbs.
In.
Lbs.
ABS ICU Mounting Bolts (To
Bracket)
11
—
97
ABS ICU Mounting Bracket
Bolts (To Frame)
23
17
200
ABS CAB Mounting Screws
(To HCU)
2
—
17
ABS Wheel Speed Sensor
Mounting Screw
12
—
105
Brake Hose Banjo Bolt (To
Caliper)
24
18
210
Brake Tube Nuts
17
—
145
Disc Brake Caliper Adapter
(To Knuckle) - Front
104
77
—
Disc Brake Caliper Adapter
(To Knuckle) - Rear
95
70
—
Disc Brake Caliper Guide
Pin Bolts - Front
35
26
—
Disc Brake Caliper Guide
Pin Bolts - Rear
22
16
192
Disc Brake Caliper Bleeder
Screw
13
—
115
Drum Brake Shoe Support
Plate Mounting Bolts
95
70
—
Drum Brake Wheel Cylinder
Mounting Bolts
13
—
115
Drum Brake Wheel Cylinder
Bleeder Screw
10
—
89
Master Cylinder Mounting
Nuts - Bosch
18
13
160
Master Cylinder Mounting
Nuts - Continental Teves
25
18
221
Parking Brake Lever
Mounting Nut And Screw
28
21
250
Power Brake Booster
Mounting Nuts
34
25
300
Proportioning Valves
27
20
239
Wheel Mounting (Lug) Nuts
135
100
—
PT
BRAKES - BASE
5 - 9
BRAKES - BASE (Continued)
SPECIAL TOOLS
BASE BRAKE SYSTEM
Cap Adapter, Brake Pressure Bleeder 6921
Adapters, Brake Pressure 8187
Tubes, Master Cylinder Bleed 8358
Adapter, Brake Pressure 8644
Adapters, Bleeder Tubes 8822
Dial Indicator C-3339
Gauge Set C-4007-A
Handle, Universal C-4171
5 - 10
BRAKES - BASE
PT
BRAKES - BASE (Continued)
BRAKE FLUID LEVEL SWITCH
DESCRIPTION
Two different master cylinders are used on this
vehicle, but the brake fluid level switch is mounted
similarly though the center of the fluid reservoir in
both (Fig. 3). Early production PT27 (convertible) use
master cylinders supplied by Bosch. Normal produc-
tion vehicles (PT27 and PT44) use master cylinders
supplied by Continental Teves.
REMOVAL
NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING) (Refer to 5 - BRAKES - CAUTION).
(1) Remove the vehicle wiring harness connector
from brake fluid level switch in master cylinder
brake fluid reservoir (Fig. 4).
(2) Push together the retaining tabs holding the
brake fluid level switch in place in the brake fluid
reservoir (Fig. 5) (Fig. 6).
(3) Pull the brake fluid level switch out the oppo-
site side of the reservoir.
Installer, Dust Boot C-4689
Fig. 3 Reservoir Mounting Screw
1 - RESERVOIR
2 - BRAKE FLUID LEVEL SWITCH
3 - RESERVOIR MOUNTING SCREW
Fig. 4 Master Cylinder
1 - POWER BRAKE BOOSTER
2 - BRAKE FLUID LEVEL SWITCH
3 - MASTER CYLINDER
Fig. 5 Master Cylinder Reservoir
1 - BRAKE FLUID LEVEL SWITCH RETAINING TABS
2 - RESERVOIR RETAINING PINS
3 - SEAL
PT
BRAKES - BASE
5 - 11
BRAKES - BASE (Continued)
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