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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 >> Removal >> Right-Hand-Drive

BOOSTER, Power Brake: Removal: 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.
NOTE: Before proceeding. See Brakes - Warning  and Brakes - Caution .
CAUTION: The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination. This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved.
  1. With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm.
  2. Disconnect the negative (ground) cable from the battery and isolate the cable.
  3. Remove the engine appearance cover.
    Fig 1: AIR CLEANER ASSEMBLY
    GC0098415Courtesy of CHRYSLER LLC
  4. Remove the air cleaner housing (1). Refer to Engine/Air Intake System/BODY, Air Cleaner - Removal
  5. Using a refrigerant recovery machine, remove the refrigerant from the air conditioning system. Refer to Heating and Air Conditioning/Plumbing - Standard Procedure .
    Fig 2: SENSOR OXYGEN UPSTREAM 1/1 2.4L
    GC0083941Courtesy of CHRYSLER LLC
  6. If equipped with a 2.4L gas engine and all-wheel-drive, remove the oxygen sensor from the top of the exhaust manifold. Refer to Fuel System/Fuel Injection/SENSOR, Oxygen - Removal
    Fig 3: ENGINE LIFT BRACKET - GAS
    GC0083942Courtesy of CHRYSLER LLC
  7. If equipped with a gas engine, perform the following:
    1. Remove the nut (1) securing the cam sensor heat shield (2) in place on the rear of the engine cylinder head. Remove the heat shield.
    2. Remove the stud securing the engine lift bracket (4) to the rear of the engine cylinder head. Remove the bracket.
    3. Disconnect the wiring connector (3) at the cam sensor and move it down out of the way.
    Fig 4: Heat Shield
    GC0083943Courtesy of CHRYSLER LLC
  8. Remove the upper and loosen the two lower fasteners (1) securing the heat shield (3) to the studs (2) located on the dash panel. Remove the heat shield.
  9. Remove the fasteners securing the coolant recovery bottle to its mounts and move it away from the power steering fluid reservoir and air conditioning liquid and suction line assembly. It is not necessary to disconnect the coolant recovery bottle fluid lines. Refer to Cooling/Engine/BOTTLE, Coolant Recovery - Removal
  10. Remove the fastener securing the power steering fluid reservoir to its mount and move it away from the air conditioning liquid and suction line assembly. It is not necessary to disconnect the power steering fluid lines. Refer to Steering/Pump/RESERVOIR, Power Steering Pump - Removal
  11. Remove the fastener securing the windshield washer reservoir to its mount and move it away from the air conditioning liquid and suction line assembly. It is not necessary to disconnect the washer fluid line. Refer to Electrical/Wipers/Washers/RESERVOIR, Windshield Washer - Removal
    Fig 5: VACUUM HOSE AT BOOSTER - RHD
    GC0098416Courtesy of CHRYSLER LLC
  12. Remove the vacuum hose routing clip (2) from the stud securing the vacuum hose to the dash panel.
  13. Disconnect the vacuum hose (3) from the check valve (1) on the power brake booster. Do not remove the check valve from the power brake booster. 
    Fig 6: A/C Liquid and Suction Line Assembly
    GC0083944Courtesy of CHRYSLER LLC
  14. Remove the nut (1) securing the air conditioning line retaining bracket (2) to the right strut tower (5).
  15. Remove the bolt (3) that secures the air conditioning liquid and suction line assembly (4) to the air conditioning evaporator (6).
  16. Disconnect the air conditioning liquid and suction line assembly from the air conditioning evaporator and remove and discard the dual-plane seals.
  17. Install plugs in, or tape over the open refrigerant line fittings and the evaporator ports.
  18. Move air conditioning liquid and suction line assembly away from the power brake booster. Use care not to bend lines.
  19. Remove the master cylinder. See Brakes/Hydraulic/Mechanical/MASTER CYLINDER, Brake - Removal 
    Fig 7: BRAKE TUBE ROUTING CLIP AT DASH PANEL
    GC0083945Courtesy of CHRYSLER LLC
  20. Remove the brake tube routing clip (2) with tubes from the stud on the dash panel (1). Do not bend the brake tubes.
  21. Remove the steering column opening cover (and airbag if equipped) on the instrument panel. Refer to Body/Instrument Panel/COVER, Steering Column Opening - Removal
    Fig 8: REINFORCEMENT
    GC0083940Courtesy of CHRYSLER LLC
  22. Remove the mounting screws (2) and reinforcement (1) behind the steering column opening cover.
  23. Remove the stop lamp switch. Refer to Electrical/Lamps/Lighting - Exterior/SWITCH, Stop Lamp - Removal
    Fig 9: BRAKE PEDAL CLIP - RHD
    GC0082338Courtesy of CHRYSLER LLC
  24. Remove the retaining clip (1) securing the power brake booster push rod (2) to the brake pedal. To do so, position a small screwdriver under the center tang of the retaining clip, then rotate the screwdriver enough to allow the retaining clip tang to pass over the end of the brake pedal pin (3). Remove and discard the clip. Do not reuse the clip. 
  25. Slide the booster push rod (2) off the brake pedal pin (3).
  26. If equipped with a manual transaxle, remove the clutch master cylinder from the pedal bracket assembly and dash panel. Refer to Clutch/CYLINDER, Clutch Master - Removal
    Fig 10: PEDAL AND BOOSTER MOUNTING - RHD
    GC0098417Courtesy of CHRYSLER LLC
  27. Remove the four nuts (4) attaching the power brake booster (1) to the dash panel.
  28. Slide the power brake booster (3) forward clearing the dash panel, then move it inboard of the brake tubes. At the same time, rotate it so the push rod on the rear of the booster is facing upward, then move it slowly across the rear of the engine compartment above the exhaust manifold. Remove the booster through the opening where the air cleaner housing is normally mounted.
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