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Home >> Chrysler >> 2008 >> PT Cruiser L4-2.4L >> Repair and Diagnosis >> Brakes and Traction Control >> Hydraulic System >> Brake Master Cylinder >> Service and Repair >> Removal and Replacement >> Master Cylinder - Installation >> Without ABS

Without ABS







LHD WITHOUT ABS





1. If removed, install the proportioning valves (1, 3) in their master cylinder ports. The valves are identical, so they can be installed in either master cylinder port going to the rear brakes. Make sure the O-rings on the proportioning valves are new. Tighten the proportioning valves to 27 Nm (20 ft. lbs.).

NOTE: The master cylinder must be bled before installing it on the vehicle.

2. Bench bleed the master cylinder. Procedures
3. Wipe the face of the power brake booster clean where the master cylinder seal comes in contact when it's installed. Do not get any cleaner or debris inside the booster.




CAUTION: When installing a master cylinder on the vehicle, a NEW vacuum seal (2) MUST be installed on the master cylinder mounting flange (1).

4. If the master cylinder does not have a NEW vacuum seal (2) installed on the mounting flange (1), remove it. Install a NEW vacuum seal on the master cylinder mounting flange making sure the seal fits squarely in its groove.

CAUTION: If resistance is met during master cylinder insertion into power brake booster, the master cylinder push rod may not be lined up with the booster push rod. Remove the master cylinder, realign and insert it again.

5. Line the master cylinder mounting holes up with the mounting studs on the power brake booster. Ensure the master cylinder piston push rod lines up with the booster push rod, then carefully slide the master cylinder into the power brake booster until it contacts the face of the booster.




6. Install the two master cylinder mounting nuts (3). Tighten each nut to 25 Nm (221 in. lbs.).




7. If equipped with a manual transaxle and a NEW reservoir is being installed, using an appropriate cutting tool, cut the clutch actuator port (3) at the center of the "V" groove (1) opening the port. Discard the severed plug (2).




8. If equipped with a manual transaxle, slide the clutch actuator hose (1) onto the reservoir port. Install the hose clamp (2) just past the upset bead (3) on the port.




9. Connect the four brake tubes (1, 3, 4, 5) to the master cylinder ports and proportioning valves (2). Tighten the tube nuts to a torque of 17 Nm (145 in. lbs.).
- Right front brake tube (1)
- Left front brake tube (3)
- Left rear brake tube (4)
- Right rear brake tube (5)





10. Connect the brake fluid level switch wiring connector (2) at the switch.
11. Install the power distribution center.
12. Connect the negative (ground) cable on the battery.
13. Install the air cleaner housing.
14. Reinstall the air cleaner cover (two clips).
15. Fill the master cylinder to the proper level. Service and Repair

WARNING: Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle. If a firm brake pedal cannot be achieved, bleed the brake hydraulic system and check for leaks. Brake Bleeding

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