Power Brake Booster - Installation - RHD
RIGHT-HAND-DRIVE - 3.6L 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 over the top center of the engine. Rotate the booster using the reverse version of how it was removed. Slide the power brake booster push rod and studs through the dash panel and into mounting position.
2. Slowly raise the right side of the engine using the floor jack (3), to a point where the right engine mount bracket can be easily installed.
3. Position the right engine mount bracket and install the two nuts (1) and three bolts (2) Engine Mount Insulator - Installation.
4. Remove the floor jack and block of wood from below engine.
5. 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.
6. Tighten the four brake pedal/booster mounting nuts in the proper sequence to 23 Nm (17 ft. lbs.).
7. 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).
8. 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.
9. Reinstall and adjust the stop lamp switch that was set aside for reuse Stop Lamp Switch - Installation
10. Install the steering column opening cover on the instrument panel. Steering Column Opening Cover - Installation
11. Install the brake tube routing clips with tubes onto the studs on the dash panel.
12. Connect the vacuum hose (2) to the check valve (1) on the power brake booster.
13. Install the master cylinder Brake Master Cylinder - Installation.
14. Install the booster vacuum hose routing clip (4) onto the master cylinder mounting stud.
15. Install the vacuum hose routing clip (3) onto the stud on the dash panel.
16. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports.
17. 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.
18. Connect the air conditioning liquid and suction line assembly to the air conditioning evaporator (6).
19. 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.).
20. 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.).
21. Install the power steering fluid reservoir. Reservoir, Power Steering Pump - Installation
22. Install the coolant recovery bottle. Coolant Recovery Bottle - Installation
23. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment.
24. Install the upper fastener (1) securing the heat shield to the dash panel. Tighten all three fasteners to 1 Nm (10 in. lbs.).
25. Install the rear cylinder head cover Cylinder Head Cover(s) - Installation.
26. Install the engine upper intake manifold Intake Manifold - Installation.
27. Install the engine appearance cover.
28. Connect the battery negative (ground) cable to its post on the battery.
29. Bleed the base brake system as necessary Service and Repair.
30. 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.
31. Road test the vehicle to ensure proper operation of the brakes.