Dodge Caliber. Manual - part 89

OPERATION

When the brake pedal is pressed, the master cylinder primary and secondary pistons apply brake pressure through
the proportioning valves (on non-ABS vehicles) and chassis brake tubes to each brake assembly. The brake fluid
reservoir supplies the brake hydraulic system with the necessary fluid to operate properly.

The non-ABS master cylinder’s primary outlet ports supply hydraulic pressure to the right front and left rear brakes
while the secondary outlet ports supply hydraulic pressure to the left front and right rear brakes. ABS equipped
master cylinder outlet ports supply hydraulic pressure to the ABS Integrated Control Unit (ICU) where it is distributed
to the individual wheel brakes.

The master cylinder reservoir cap diaphragm is slit to allow atmospheric pressure to equalize on both sides of the
diaphragm.

STANDARD PROCEDURE

MASTER CYLINDER BLEEDING

NOTE: On vehicles without ABS this procedure is designed to be performed with the proportioning valves
installed in the master cylinder.

1. Clamp the master cylinder in a vise with soft-jaw caps.

2. Master Cylinder without ABS – Attach the special

tools for bleeding the master cylinder in the follow-
ing fashion:

a. Thread Bleeder Tube Adapter (1), Special Tool

8822-1, into the primary outlet port of the mas-
ter cylinder without a proportioning valve.
Tighten Adapter to 17 N·m (150 in. lbs.).

b. Thread Bleeder Tube Adapter (2), Special Tool

8822-2, into the secondary outlet port of the
master cylinder without a proportioning valve.
Tighten Adapter to 17 N·m (150 in. lbs.).

c. Thread Bleeder Tube Adapter (4), Special Tool

8822-1, into the proportioning valve in the
lower secondary outlet port of the master cylin-
der. Tighten Adapter to 17 N·m (150 in. lbs.).

d. Thread Bleeder Tube Adapter (5), Special Tool

8822-2, into the proportioning valve in the
lower primary outlet port of the master cylinder.
Tighten Adapter to 17 N·m (150 in. lbs.).

e. Thread a Bleeder Tube (6), Special Tool 8358-1, into each Adapter. Tighten tube nuts to 17 N·m (150 in.

lbs.).

f. Install Bleeder Tubes Adapter (3), Special Tool 9705, in place of the fill cap as shown.

g. Flex and place the open ends of the Bleeder Tubes into open hose tips on Adapter 9705. Be sure Bleeder

Tubes are inserted into Adapter 9705 far enough not to come loose during bleed procedure.

BRAKES - BASE

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3. Master Cylinder with ABS – Attach the special tools

for bleeding the master cylinder in the following
fashion:

a. Thread Bleeder Tube Adapters (3), Special

Tool 8822-2, into the primary and secondary
outlet ports of the master cylinder. Tighten
Adapters to 17 N·m (150 in. lbs.).

b. Thread a Bleeder Tube (2), Special Tool

8358-1, into each Adapter. Tighten tube nuts to
17 N·m (150 in. lbs.).

c. Flex each Bleeder Tube and place the open

ends into the neck of the master cylinder res-
ervoir. Position the open ends of the tubes into
the reservoir so their outlets are below the sur-
face of the brake fluid in the reservoir when
filled.

NOTE: Make sure the ends of the Bleeder Tubes stay below the surface of the brake fluid in the reservoir at
all times during the bleeding procedure.

4. Fill the brake fluid reservoir with fresh Mopar

Brake Fluid DOT 3 Motor Vehicle, or equivalent. (Refer to 5 -

BRAKES/HYDRAULIC/MECHANICAL/FLUID - SPECIFICATIONS)

5. Using an appropriately sized wooden dowel as a pushrod, slowly press the pistons inward discharging brake fluid

through the Bleeder Tubes, then release the pressure, allowing the pistons to return to the released position.
Repeat this several times until all air bubbles are expelled from the master cylinder bore and Bleeder Tubes.

6. Remove the Bleeder Tubes and Adapters from the master cylinder and plug the master cylinder outlet ports.

7. Install the fill cap on the reservoir.

8. Remove the master cylinder from the vise.

9. Install the master cylinder on the vehicle. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/MASTER CYLIN-

DER - INSTALLATION)

REMOVAL

LEFT-HAND-DRIVE WITH ABS

NOTE: Before proceeding, (Refer to 5 - BRAKES - WARNING) (Refer to 5 - BRAKES - CAUTION).

CAUTION: The vacuum in the power brake booster must be pumped down before removing the master cyl-
inder 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.

5 - 58

BRAKES - BASE

3. Disconnect the wiring harness connector (1) from

the brake fluid level switch (2) in the master cylin-
der brake fluid reservoir.

4. Disconnect the primary (1) and secondary (2)

brake tubes at the master cylinder outlet ports.
Install plugs at all of the open brake tube outlets on
the master cylinder.

5. If equipped with a manual transaxle, remove the

clamp and slide the clutch actuator hose (2) off the
reservoir port (1).

BRAKES - BASE

5 - 59

6. Clean the area around where the master cylinder

(2) attaches to the power brake booster (1) using a
suitable brake cleaner such as Mopar

Brake Parts

Cleaner or an equivalent.

7. Remove the two nuts (3) attaching the master cyl-

inder (2) to the power brake booster (1).

8. Slide the master cylinder straight out of the power

brake booster.

LEFT-HAND-DRIVE WITHOUT ABS

NOTE: Before proceeding, (Refer to 5 - BRAKES - WARNING) (Refer to 5 - BRAKES - CAUTION).

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 wiring harness connector (1) from the

brake fluid level switch (2) in the master cylinder
brake fluid reservoir.

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BRAKES - BASE

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