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Booster, Power Brake: Installation: Right-Hand-Drive

WARNING: This page is about a different car, the 2016 Dodge Journey and 2015 Dodge Journey. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Booster Seal
GC0082140Courtesy of CHRYSLER GROUP, 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 GROUP, LLC
  1. Install the power brake booster (1) into the engine compartment using the reverse version of how it was removed. 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: Brake Pedal/Booster Mounting Nuts Tightening Sequence - RHD
    GC0082344Courtesy of CHRYSLER GROUP, 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.
    Fig 4: Brake Pedal Clip - RHD
    GC0082338Courtesy of CHRYSLER GROUP, LLC
  5. Using Mopar® Lubriplate, 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. 
    Fig 5: Stop Lamp Switch Installation
    GC0128489Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    Do not reuse the original stop lamp switch on vehicles built prior to July 21, 2008. Anytime a switch has been removed or its position compromised, a new switch must be installed and adjusted. Do not attempt to readjust the switch. The original brake lamp switch can be reused and adjusted on vehicles built on or after July 21, 2008.

  7. Install and adjust a NEW stop lamp switch (2) in the brake pedal bracket (1) on vehicle built prior to July 21, 2008. The original brake lamp switch can be reused on vehicles built on or after July 21, 2008. Refer to SWITCH, STOP LAMP, INSTALLATION .
  8. Install the brake tube routing clips with tubes onto the studs on the dash panel.
    Fig 6: Vacuum Hose At Booster - RHD
    GC0120815Courtesy of CHRYSLER GROUP, LLC
  9. Connect the vacuum hose (2) to the check valve (1) on the power brake booster.
  10. Install the master cylinder. Refer to MASTER CYLINDER, BRAKE, INSTALLATION .
    Fig 7: Vacuum Hose At Booster - RHD
    GC0120815Courtesy of CHRYSLER GROUP, LLC
  11. Install the booster vacuum hose routing clip (4) onto the master cylinder mounting stud.
  12. Install the vacuum hose routing clip (3) onto the stud on the dash panel.
    Fig 8: Wiper Module Bolts & Wiper Motor Connector
    GC0128488Courtesy of CHRYSLER GROUP, LLC
  13. Place the wiper module into position, install the three mounting bolts (1), Tighten bolts to 11 N.m (97 in. lbs.).
  14. Connect the electrical connector (2) to the wiper motor.
    Fig 9: Wheelhouse Brace
    GC0128486Courtesy of CHRYSLER GROUP, LLC
  15. Install the wheelhouse brace (2). Install and tighten the eight mounting bolts (four each side) (1) to 48 N.m (35 ft. lbs.).
    Fig 10: Cowl Screen
    GC0128455Courtesy of CHRYSLER GROUP, LLC
  16. Install the cowl screen. Install the push-pins (1) securing the cowl screen to the wheelhouse brace and cowl. Rotate the screw (2) in the center of the cowl screen 90° counterclockwise to lock the screen in place.
  17. Install the wiper arms. Refer to ARM, WIPER, INSTALLATION .
    Fig 11: Cowl Top Screen
    GC0128454Courtesy of CHRYSLER GROUP, LLC
  18. Install the cowl top screen (3). Install the two push-pins (1) securing the cowl top screen at the ends. Install the remaining push-pins (2).
  19. Install the engine appearance cover.
  20. Connect the battery negative (ground) cable to its post on the battery.
  21. Bleed the base brake system as necessary. Refer to STANDARD PROCEDURE  .
    WARNING:

    Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle.

  22. Road test the vehicle to ensure proper operation of the brakes.
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