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Right-Hand-Drive - 3.6L Gas Engine

WARNING: This page is about a different car, the 2013 Dodge Avenger and 2013 Chrysler 200. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:

Before proceeding, refer to WARNING .

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.
  4. Remove the engine upper intake manifold. Refer to 2.4L MANIFOLD, INTAKE, REMOVAL or 3.6L MANIFOLD, INTAKE, REMOVAL .
  5. Using a refrigerant recovery machine, remove the refrigerant from the air conditioning system.
  6. Remove the rear cylinder head cover . Refer to 2.4L COVER(S), CYLINDER HEAD, REMOVAL or 3.6L COVER(S), CYLINDER HEAD, REMOVAL .
    Fig 1: Heat Shield
    GC0083943Courtesy of CHRYSLER GROUP, LLC
  7. 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.
  8. 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 BOTTLE, COOLANT RECOVERY, REMOVAL .
  9. 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 RESERVOIR, POWER STEERING PUMP, REMOVAL .
    Fig 2: Vacuum Hose At Booster - RHD
    GC0120815Courtesy of CHRYSLER GROUP, LLC
  10. Remove the booster vacuum hose routing clip (4) from the master cylinder mounting stud.
  11. Remove the vacuum hose routing clip (3) from the stud on the dash panel.
    Fig 3: A/C Liquid And Suction Line Assembly
    GC0083944Courtesy of CHRYSLER GROUP, LLC
  12. Remove the nut (1) securing the air conditioning line retaining bracket (2) to the right strut tower (5).
  13. Remove the bolt (3) that secures the air conditioning liquid and suction line assembly (4) to the air conditioning evaporator (6).
  14. Disconnect the air conditioning liquid and suction line assembly from the air conditioning evaporator and remove and discard the dual-plane seals.
  15. Install plugs in, or tape over the open refrigerant line fittings and the evaporator ports.
  16. Move air conditioning liquid and suction line assembly away from the power brake booster. Use care not to bend lines.
  17. Remove the master cylinder. Refer to MASTER CYLINDER, BRAKE, REMOVAL .
    Fig 4: Vacuum Hose At Booster - RHD
    GC0120815Courtesy of CHRYSLER GROUP, LLC
  18. Disconnect the vacuum hose (2) from the check valve (1) on the power brake booster. Do not remove the check valve from the power brake booster. 
  19. Remove both brake tube routing clips with tubes from the studs on the dash panel. Do not bend the brake tubes.
  20. Remove the steering column opening cover on the instrument panel. Refer to COVER, STEERING COLUMN OPENING, REMOVAL .
  21. Remove the stop lamp switch. Refer to SWITCH, STOP LAMP, REMOVAL .
    NOTE:

    Do not discard the stop lamp switch as it can be adjusted and reinstalled. 

    Fig 5: Brake Pedal Clip - RHD
    GC0082338Courtesy of CHRYSLER GROUP, LLC
  22. 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. 
  23. Slide the booster push rod (2) off the brake pedal pin (3).
    Fig 6: Pedal And Booster Mounting - RHD
    GC0098417Courtesy of CHRYSLER GROUP, LLC
  24. Remove the four nuts (4) attaching the power brake booster (1) to the dash panel.
    Fig 7: Jack Supporting Oil Pan
    GC0120816Courtesy of CHRYSLER GROUP, LLC
  25. Position a floor jack (3) with an appropriate size block of wood (2) below the engine oil pan (1). raise the jack until the block of wood just comes into contact with the bottom of the oil pan, but no further.
    Fig 8: Identifying Right Engine Mount Bracket
    GC0120817Courtesy of CHRYSLER GROUP, LLC
  26. Remove the two nuts (1) and three bolts (2) securing the right engine mount bracket.
    Fig 9: Jack Supporting Oil Pan
    GC0120816Courtesy of CHRYSLER GROUP, LLC
  27. Slowly lower the right side of the engine using the floor jack (3) until enough room is gained for booster removal over rear of engine.
    Fig 10: Pedal And Booster Mounting - RHD
    GC0098417Courtesy of CHRYSLER GROUP, LLC
  28. Slide the power brake booster (1) 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 outward. Remove the booster out over the center of the engine.
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