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BOOSTER, Power Brake: Installation: Right-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 - RHD
GC0098417Courtesy of CHRYSLER LLC
  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.
    Fig 3: MOUNTING NUT TORQUE SEQUENCE - RHD
    GC0082344Courtesy 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 four brake pedal/booster mounting nuts in the proper sequence to 23 N.m (17 ft. lbs.).
  4. If equipped with a manual transaxle, install the clutch master cylinder on the dash panel and clutch pedal bracket assembly. Refer to Clutch/CYLINDER, Clutch Master - Installation
    Fig 4: BRAKE PEDAL CLIP - RHD
    GC0082338Courtesy of CHRYSLER LLC
  5. Using Mopar® Lubricate, or an equivalent, coat the surface of the brake pedal pin (3) where it contacts the brake booster input rod (2).
  6. 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. 
  7. 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
  8. Install the steering column opening cover reinforcement (1) in the steering column opening. Install the mounting screws (2).
  9. 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: BRAKE TUBE ROUTING CLIP AT DASH PANEL
    GC0083945Courtesy of CHRYSLER LLC
  10. Install the brake tube routing clip (2) with tubes onto the stud on the dash panel (1).
  11. Install the master cylinder. See Brakes/Hydraulic/Mechanical/MASTER CYLINDER, Brake - Installation 
    Fig 7: air conditioning Liquid and Suction Line Assembly
    GC0083944Courtesy of CHRYSLER LLC
  12. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports.
  13. 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.
  14. Connect the air conditioning liquid and suction line assembly to the air conditioning evaporator (6).
  15. Install the bolt (3) that secures the air conditioning liquid and suction line assembly to the air conditioning evaporator. Tighten the bolt to 12 N.m (105 in. lbs.).
  16. 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 N.m (40 in. lbs.).
    Fig 8: VACUUM HOSE AT BOOSTER - RHD
    GC0098416Courtesy 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.
  17. Connect the vacuum hose (3) to the vacuum check valve (1).
  18. Push the vacuum hose routing clip (2) onto the stud securing the vacuum hose to the dash panel.
  19. Install the windshield washer reservoir. Refer to Electrical/Wipers/Washers/RESERVOIR, Windshield Washer - Installation
  20. Install the power steering fluid reservoir. Refer to Steering/Pump/RESERVOIR, Power Steering Pump - Installation
  21. Install the coolant recovery bottle. Refer to Cooling/Engine/BOTTLE, Coolant Recovery - Installation
    Fig 9: Heat Shield
    GC0083943Courtesy of CHRYSLER LLC
  22. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment.
  23. Install the upper fastener (1) securing the heat shield to the dash panel. Tighten all three fasteners to 1 N.m (10 in. lbs.).
    Fig 10: ENGINE LIFT BRACKET - GAS
    GC0083942Courtesy of CHRYSLER LLC
  24. If equipped with a gas engine, perform the following:
    1. Install the engine lift bracket (4) on the rear of the engine cylinder head with its mounting stud.
    2. Position the cam sensor heat shield (2) over the engine lift bracket mounting stud and secure it in place with its mounting nut (1).
    3. Connect the wiring connector (3) to the cam sensor.
    Fig 11: SENSOR OXYGEN UPSTREAM 1/1 2.4L
    GC0083941Courtesy of CHRYSLER LLC
  25. If equipped with a 2.4L gas engine and all-wheel-drive, install the oxygen sensor in the top of the exhaust manifold. Refer to Fuel System/Fuel Injection/SENSOR, Oxygen - Installation
    Fig 12: AIR CLEANER ASSEMBLY
    GC0098415Courtesy of CHRYSLER LLC
  26. Install the air cleaner housing (1). Refer to Engine/Air Intake System/BODY, Air Cleaner - 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. See Brakes - Standard Procedure 
  30. Using a refrigerant recovery machine, evacuate and charge the refrigerant system. Refer to Heating and Air Conditioning/Plumbing - Standard Procedure
    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.
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