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Home >> Chrysler >> 2009 >> PT Cruiser Limited >> Repair and Diagnosis >> External Pages >> Different car >> Section 8 (Mechanical Brake System - Base (Service Information)) >> Hydraulic/Mechanical >> BOOSTER, Power Brake >> Installation >> Left-Hand Drive

Left-Hand Drive

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.
Fig 1: BOOSTER SEAL
GC0082140Courtesy of CHRYSLER LLC
NOTE: Before power brake booster (1) installation, be certain a NEW dash seal (2) is installed on the booster mounting studs.
Fig 2: PEDAL AND BOOSTER MOUNTING - LHD
GC0082337Courtesy of CHRYSLER LLC
  1. Install the power brake booster (3) by sliding the 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.
    Fig 3: MOUNTING NUT TORQUE SEQUENCE
    GC0082343Courtesy of CHRYSLER LLC
    CAUTION: Because of power brake booster design, it is very important to tighten the mounting nuts in the proper sequence.
  3. Tighten the brake pedal/booster mounting nuts in the proper sequence to 23 N.m (17 ft. lbs.).
    Fig 4: BRAKE PEDAL CLIP
    GC0082336Courtesy of CHRYSLER LLC
  4. Using Mopar® Lubricate, or an equivalent, coat the surface of the brake pedal pin (3) where it contacts the brake booster input rod (1).
  5. 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. 
  6. Install and adjust the stop lamp switch in the brake pedal bracket. Refer to Electrical/Lamps/Lighting - Exterior/SWITCH, Stop Lamp - Installation
    Fig 5: REINFORCEMENT
    GC0083940Courtesy of CHRYSLER LLC
  7. Install the steering column opening cover reinforcement (1) in the steering column opening. Install the mounting screws (2).
  8. Install the steering column opening cover (and airbag if equipped) on the instrument panel. Refer to Body/Instrument Panel/COVER, Steering Column Opening - Installation
    Fig 6: VACUUM HOSE AT BOOSTER - LHD
    GC0083939Courtesy of CHRYSLER LLC
    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.
  9. Connect the vacuum hose (2) to the vacuum check valve (1).
  10. Install the master cylinder. See Brakes/Hydraulic/Mechanical/MASTER CYLINDER, Brake - Installation 
  11. Connect the battery negative cable to its post on the battery.
  12. Bleed the base brake system if necessary. See Brakes - Standard Procedure 
    WARNING: Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle.
  13. Road test the vehicle to ensure proper operation of the brakes.
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