Chrysler PT Cruiser. Manual — part 424
(5) Install the two master cylinder mounting nuts
(Fig. 78). Bosch Master Cylinder – Tighten each nut
to 18 N·m (160 in. lbs.). Continental Teves Master
Cylinder – Tighten each nut to 25 N·m (221 in. lbs.).
(6) Continental Teves Master Cylinder Only – If
equipped with a manual transaxle and a new reser-
voir is being installed, using an appropriate cutting
tool, cut the clutch actuator port at “V” groove open-
ing the port. Discard the severed plug (Fig. 92).
(7) Continental Teves Master Cylinder Only – If
equipped with a manual transaxle, slide the clutch
actuator hose onto the reservoir port (Fig. 93). Install
the hose clamp just past the upset bead on the port.
(8) Connect the primary and secondary brake
tubes to the master cylinder outlet ports (Fig. 76).
Tighten tube nuts to 17 N·m (145 in. lbs.).
(9) Connect the brake fluid level switch wiring
connector (Fig. 75).
(10) Install the power distribution center.
(11) Connect the negative (ground) cable on the
battery.
(12) Install the air cleaner housing.
(13) Reinstall the air cleaner cover.
(14) Fill the master cylinder reservoir to the
proper level. (Refer to 5 - BRAKES/HYDRAULIC/
MECHANICAL/FLUID - STANDARD PROCEDURE)
WARNING:
Be
certain
a
firm
brake
pedal
is
achieved prior to attempting to operate the vehicle.
If a firm brake pedal cannot be achieved, bleed the
brake hydraulic system and check for leaks. (Refer
to 5 - BRAKES - STANDARD PROCEDURE)
(15) Road test the vehicle to ensure proper opera-
tion of the brakes.
Fig. 91 Vacuum Seal On Rear Of Master Cylinder
1 - MASTER CYLINDER MOUNTING FLANGE
2 - VACUUM SEAL
Fig. 92 Cut And Remove End Of Port - Manual
Transaxle Only
1 - CUT AT CENTER OF
9
V
9
GROOVE
2 - PORT PLUG
3 - HYDRAULIC CLUTCH PORT
Fig. 93 Clutch Actuator Hose To Reservoir Port
Installation
1 - CLUTCH ACTUATOR HOSE
2 - HOSE CLAMP
3 - UPSET BEAD ON PORT
5 - 48
BRAKES - BASE
PT
MASTER CYLINDER (Continued)
INSTALLATION - LHD WITHOUT ABS
(1) If removed, install the proportioning valves in
their master cylinder ports (Fig. 83). The valves are
identical, so they can be installed in either master
cylinder port going to the rear brakes. Make sure the
O-rings on the proportioning valves are new. Tighten
the proportioning valves to 27 N·m (239 in. lbs.).
NOTE: The master cylinder must be bled before
installing it on the vehicle.
(2) Bleed the master cylinder. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/MASTER
CYLINDER - STANDARD PROCEDURE)
(3) Wipe the face of the power brake booster clean
where the master cylinder seal comes in contact
when it’s installed. Do not get any cleaner or debris
inside the booster.
CAUTION: When installing a master cylinder on the
vehicle, a NEW vacuum seal MUST be installed on
master cylinder (Fig. 94).
(4) If the master cylinder does not have a new vac-
uum seal installed on the mounting flange, remove it.
Install a NEW vacuum seal on the master cylinder
mounting flange making sure the seal fits squarely
in its groove (Fig. 94).
CAUTION: If resistance is met during master cylin-
der insertion into power brake booster, the master
cylinder push rod may not be lined up with the
booster push rod. Remove the master cylinder,
realign and insert it again.
(5) Line the master cylinder mounting holes up
with the mounting studs on the power brake booster.
Ensure the master cylinder piston push rod lines up
with the booster push rod, then carefully slide the
master cylinder into the power brake booster until it
contacts the face of the booster.
(6) Install the two master cylinder mounting nuts
(Fig. 82). Bosch Master Cylinder – Tighten each nut
to 18 N·m (160 in. lbs.). Continental Teves Master
Cylinder – Tighten each nut to 25 N·m (221 in. lbs.).
(7) Continental Teves Master Cylinder Only – If
equipped with a manual transaxle and a new reser-
voir is being installed, using an appropriate cutting
tool, cut the clutch actuator port at the “V” groove
opening the port. Discard the severed plug (Fig. 95).
(8) Continental Teves Master Cylinder Only – If
equipped with a manual transaxle, slide the clutch
actuator hose onto the reservoir port (Fig. 96). Install
the hose clamp just past the upset bead on the port.
(9) Connect the four brake tubes to the master cyl-
inder and proportioning valve ports (Fig. 80). Tighten
the tube nuts to a torque of 17 N·m (145 in. lbs.).
(10) Connect the brake fluid level switch wiring
connector (Fig. 79).
(11) Install the power distribution center.
(12) Connect the negative (ground) cable on the
battery.
(13) Install the air cleaner housing.
(14) Reinstall the air cleaner cover (two clips).
(15) Fill the master cylinder to the proper level.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
FLUID - STANDARD PROCEDURE)
Fig. 94 Vacuum Seal On Rear Of Master Cylinder
1 - MASTER CYLINDER MOUNTING FLANGE
2 - VACUUM SEAL
Fig. 95 Cut And Remove End Of Port - Manual
Transaxle Only
1 - CUT AT CENTER OF
9
V
9
GROOVE
2 - PORT PLUG
3 - HYDRAULIC CLUTCH PORT
PT
BRAKES - BASE
5 - 49
MASTER CYLINDER (Continued)
WARNING:
Be
certain
a
firm
brake
pedal
is
achieved prior to attempting to operate the vehicle.
If a firm brake pedal cannot be achieved, bleed the
brake hydraulic system and check for leaks. (Refer
to 5 - BRAKES - STANDARD PROCEDURE)
(16) Road test the vehicle to ensure proper opera-
tion of the brakes.
INSTALLATION - RHD
NOTE: The master cylinder must be bled before
installing it on the vehicle.
(1) Bleed the master cylinder. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/MASTER
CYLINDER - STANDARD PROCEDURE)
(2) Wipe the face of the power brake booster clean
where the master cylinder seal comes in contact
when it’s installed. Do not get any cleaner or debris
inside the booster.
CAUTION: When installing a master cylinder on the
vehicle, a NEW vacuum seal MUST be installed on
master cylinder (Fig. 97).
(3) If the master cylinder does not have a new vac-
uum seal installed on the mounting flange, remove it.
Install a NEW vacuum seal on the master cylinder
mounting flange making sure the seal fits squarely
in its groove (Fig. 97).
CAUTION: If resistance is met during master cylin-
der insertion into power brake booster, the master
cylinder push rod may not be lined up with the
booster push rod. Remove the master cylinder,
realign and insert it again.
(4) Line the master cylinder mounting holes up
with the mounting studs on the power brake booster.
Ensure the master cylinder piston push rod lines up
with the booster push rod, then carefully slide the
master cylinder into the power brake booster until it
contacts the face of the booster.
(5) Install the two master cylinder mounting nuts
(Fig. 86). Bosch Master Cylinder – Tighten each nut
to 18 N·m (160 in. lbs.). Continental Teves Master
Cylinder – Tighten each nut to 25 N·m (221 in. lbs.).
(6) Continental Teves Master Cylinder Only – If
equipped with a manual transaxle and a new reser-
voir is being installed, using an appropriate cutting
tool, cut the clutch actuator port at “V” groove open-
ing the port. Discard the severed plug (Fig. 98).
(7) Continental Teves Master Cylinder Only – If
equipped with a manual transaxle, slide the clutch
actuator hose onto the reservoir port (Fig. 99). Install
the hose clamp just past the upset bead on the port.
(8) Connect the primary and secondary brake
tubes to the master cylinder (Fig. 84). Tighten all
tube nuts to 17 N·m (145 in. lbs.).
(9) Connect the brake fluid level switch wiring
connector.
(10) Install the brake booster vacuum supply hose.
(11) Fill the master cylinder to the proper level.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
FLUID - STANDARD PROCEDURE)
Fig. 96 Clutch Actuator Hose To Reservoir Port
Installation
1 - CLUTCH ACTUATOR HOSE
2 - HOSE CLAMP
3 - UPSET BEAD ON PORT
Fig. 97 Vacuum Seal On Rear Of Master Cylinder
1 - MASTER CYLINDER MOUNTING FLANGE
2 - VACUUM SEAL
5 - 50
BRAKES - BASE
PT
MASTER CYLINDER (Continued)
WARNING:
Be
certain
a
firm
brake
pedal
is
achieved prior to attempting to operate the vehicle.
If a firm brake pedal cannot be achieved, bleed the
brake hydraulic system and check for leaks. (Refer
to 5 - BRAKES - STANDARD PROCEDURE)
(12) Road test the vehicle to ensure proper opera-
tion of the brakes.
PEDAL - WITH AUTOMATIC
TRANSAXLE
REMOVAL
NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING).
(1) Unclip the air cleaner cover (two clips) and
move the cover aside.
(2) Disconnect and isolate the battery negative
cable from its post on the battery.
(3) Remove the silencer pad below the knee
blocker.
(4) Fold down and remove the knee blocker.
(5) Remove the brake lamp switch by rotating the
switch in a counterclockwise direction approximately
30 degrees (Fig. 100).
(6) Pull the switch rearward and remove it from
its mounting bracket. Discard the brake lamp switch.
(7) Remove the clip securing the power brake
booster input rod to the brake pedal (Fig. 101).
Remove the input rod from the brake pedal.
(8) Remove the four nuts securing the power brake
booster to the brake pedal bracket (Fig. 101).
(9) Remove the two remaining upper nuts securing
the brake pedal bracket to the instrument panel sup-
port.
(10) Carefully remove the brake pedal and bracket
assembly from the vehicle.
(11) Remove the pivot shaft nut.
Fig. 98 Cut And Remove End Of Port - Manual
Transaxle Only
1 - CUT AT CENTER OF
9
V
9
GROOVE
2 - PORT PLUG
3 - HYDRAULIC CLUTCH PORT
Fig. 99 Clutch Actuator Hose To Reservoir Port
Installation
1 - CLUTCH ACTUATOR HOSE
2 - HOSE CLAMP
3 - UPSET BEAD ON PORT
Fig. 100 Brake Lamp Switch
1 - BRAKE LAMP SWITCH
2 - STEERING COLUMN COUPLER
3 - BRAKE PEDAL
PT
BRAKES - BASE
5 - 51
MASTER CYLINDER (Continued)
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