CYLINDER, Clutch Master, LHD: Installation: Installation
WARNING: This page is about a different car, the 2009 Dodge Caliber. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash it off immediately with water.
- Install clutch master cylinder body (4) to the clutch pedal bracket assembly and 1/4 turn counter clockwise to secure.
- Insert hydraulic tube (6) into master cylinder pressure line connector (5) and install retaining clip.
- Connect clutch master cylinder rod (3) to clutch pedal pin. An audible "click" should be heard.
NOTE: Before power brake booster (1) installation, be certain a NEW dash seal (2) is installed on the booster mounting studs.
- Install the power brake booster (3) by sliding the push rod and studs through the dash panel and into mounting position.
- 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.
- Tighten the brake pedal/booster mounting nuts in the proper sequence to 23 N.m (17 ft. lbs.).
- Using Mopar® Lubriplate, or an equivalent, coat the surface of the brake pedal pin (3) where it contacts the brake booster input rod (1).
- Install the power brake booster push rod (1) on the pin (3) mounted on the side of the brake pedal. Install a NEW retaining clip (2) on the end of the pin. Do not reuse the old clip.
- Install and adjust the stop lamp switch in the brake pedal bracket. Refer to Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/SWITCH, Stop Lamp - Installation .
- Install the steering column cover reinforcement (1) (if equipped) using the four mounting screws (2).
- Install the steering column opening cover on the instrument panel.
CAUTION: When installing the vacuum hose on the check valve (1), make sure the hose is routed properly to avoid possible contact with unfriendly surfaces.
- Connect the vacuum hose (2) to the vacuum check valve (1).
- Install the relay bracket (2) to the fuel filter (3) using mounting bolt (1) (if equipped).
- Install the tube bundle routing clip (with tubes) onto the stud on the left side of the dash panel.
- Connect the rear brake tubes (1) to the junction block (2). Tighten the tube nuts to 17 N.m (150 in. lbs.).
- Install the left front brake tube into the clip located on the left body rail.
- Install the master cylinder. Refer to Brakes/Hydraulic/Mechanical/MASTER CYLINDER, Brake - Installation .
- Verify that brake master cylinder reservoir (1) is full. Top off with DOT 3 brake fluid if necessary.
- Reposition the PCM and bracket (4) into mounting position (if equipped).
- Install bolt (2) for the PCM mounting bracket to lower shock tower and tighten to 9 N.m (80 in. lbs.) (if equipped).
- Install nut (1) for the PCM mounting bracket to upper shock tower stud and tighten to 9 N.m (80 in. lbs.) (if equipped).
- Connect battery negative cable. Refer to Electrical - Engine Systems/Battery System/CABLES, Battery - Installation .
- Bleed the base brake system. Refer to Brakes - Standard Procedure .
- Bleed clutch system. See Clutch - Standard Procedure .
- Actuate clutch pedal a minimum of fifteen times to allow any air ingested into the system to vent to the master cylinder reservoir.
- Install the air cleaner cover (3) and the air intake hose (2) to the hose (1) leading down the back of the engine.
- Road test the vehicle to ensure proper operation of the clutch and brakes.