Power Brake Booster - Installation - RHD
RIGHT-HAND-DRIVE - 2.0L/2.4L GAS ENGINE
NOTE: Before power brake booster (1) installation, be certain a NEW dash seal (2) is installed on the booster mounting studs.
1. Install the power brake booster (1) into the engine compartment where the air cleaner housing is normally mounted. Rotate the booster so the push rod on the rear is facing upward, then move the booster slowly across the rear of the engine compartment above the exhaust manifold. Once past the exhaust manifold, rotate the booster and move it past the brake tubes. Slide the power brake booster push rod and studs through the dash panel and into mounting position.
2. Under the instrument panel, install the four power brake booster mounting nuts (4). To tighten the nuts, refer to the following step.
CAUTION: Because of power brake booster design, it is very important to tighten the mounting nuts in the proper sequence.
3. Tighten the four brake pedal/booster mounting nuts in the proper sequence to 23 Nm (17 ft. lbs.).
4. Using Mopar(R) Lubriplate, or an equivalent, coat the surface of the brake pedal pin (3) where it contacts the brake booster input rod (2).
5. Install the power brake booster push rod (2) on the pin (3) mounted on the side of the brake pedal. Install a NEW retaining clip (1) on the end of the pin. Do not reuse the old clip.
6. Install and adjust the stop lamp switch in the brake pedal bracket Stop Lamp Switch - Installation
7. Install the steering column opening cover on the instrument panel Steering Column Opening Cover - Installation.
8. Install the brake tube routing clips with tubes onto the studs on the dash panel.
9. Connect the vacuum hose (2) to the check valve (1) on the power brake booster.
10. Install the master cylinder Brake Master Cylinder - Installation
11. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports.
12. Lubricate the rubber O-rings on new dual-plan seals with clean refrigerant oil and install the seals onto the liquid and suction line fittings. Use only the specified seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the air conditioning compressor in the vehicle.
13. Connect the air conditioning liquid and suction line assembly to the air conditioning evaporator (6).
14. Install the bolt (3) that secures the air conditioning liquid and suction line assembly to the air conditioning evaporator. Tighten the bolt to 12 Nm (105 in. lbs.).
15. Install the nut (1) that secures the air conditioning line bracket (2) to the right front strut tower (5). Tighten the nut to 4.5 Nm (40 in. lbs.).
16. Install the booster vacuum hose routing clip (4) onto the master cylinder mounting stud.
17. Install the vacuum hose routing clip (3) onto the stud on the dash panel.
18. Install the power steering fluid reservoir Reservoir, Power Steering Pump - Installation.
19. Install the coolant recovery bottle Coolant Recovery Bottle - Installation.
20. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment.
21. Install the upper fastener (1) securing the heat shield to the dash panel. Tighten all three fasteners to 1 Nm (10 in. lbs.).
22. Install the engine lift bracket (4) on the rear of the engine cylinder head with its mounting stud.
23. Position the cam sensor heat shield (2) over the engine lift bracket mounting stud and secure it in place with its mounting nut (1).
24. Connect the wiring connector (3) to the cam sensor.
25. Install the engine appearance cover.
26. Connect the battery negative (ground) cable to its post on the battery.
27. Bleed the base brake system as necessary Service and Repair.
28. Using a refrigerant recovery machine, evacuate and charge the refrigerant system Refrigerant System Charge.
WARNING: Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle.
29. Road test the vehicle to ensure proper operation of the brakes.