Dodge Journey: Installation

LEFT-HAND-DRIVE

Brakes
Fig. 35: BOOSTER SEAL

NOTE: Before power brake booster (1) installation, be certain a NEW dash seal (2) is installed on the booster mounting studs.

Brakes
Fig. 36: PEDAL AND BOOSTER MOUNTING - LHD

1. Install the power brake booster (3) by sliding the 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.

Brakes
Fig. 37: MOUNTING NUT TORQUE SEQUENCE

CAUTION: Because of power brake booster design, it is very important to tighten the mounting nuts in the proper sequence.

3. Tighten the brake pedal/booster mounting nuts in the proper sequence to 23 N.m (17 ft. lbs.).

Brakes
Fig. 38: BRAKE PEDAL CLIP

4. Using Mopar Lubriplate, or an equivalent, coat the surface of the brake pedal pin (3) where it contacts the brake booster input rod (1)

5. Install the power brake booster push rod (1) on the pin (3) mounted on the side of the brake pedal. Install a NEW retaining clip (2) on the end of the pin. Do not reuse the old clip.

Brakes
Fig. 39: STOP LAMP SWITCH AND PEDAL CLIP

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.

6. 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. 7. If equipped, install the silencer pad below the instrument panel.

Brakes
Fig. 40: VACUUM HOSE AT BOOSTER - LHD

CAUTION: When installing the vacuum hose on the check valve (1), make sure the hose is routed properly to avoid possible contact with unfriendly surfaces.

8. Connect the vacuum hose (2) to the vacuum check valve (1).

Brakes
Fig. 41: REAR BRAKE TUBES AT JUNCTION BLOCK

9. Connect the rear brake tubes (1) to the junction block (2). Tighten the tube nuts to 17 N.m (150 in. lbs.).

10. Install the master cylinder.

Brakes
Fig. 42: WHEELHOUSE BRACE

11. Install the wheelhouse brace (2). Install and tighten the eight mounting bolts (four each side) (1) to 48 N.m (35 ft. lbs.).

Brakes
Fig. 43: COWL SCREEN

12. 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 90º counterclockwise to lock the screen in place.

13. Install the wiper arms.

Brakes
Fig. 44: COWL TOP SCREEN

14. 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).

15. Connect the battery negative cable to its post on the battery.

16. Bleed the base brake system.

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

RIGHT-HAND-DRIVE

Brakes
Fig. 45: BOOSTER SEAL

NOTE: Before power brake booster (1) installation, be certain a NEW dash seal (2) is installed on the booster mounting studs.

Brakes
Fig. 46: PEDAL AND BOOSTER MOUNTING - RHD

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.

Brakes
Fig. 47: MOUNTING NUT TORQUE SEQUENCE - RHD

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.

Brakes
Fig. 48: BRAKE PEDAL CLIP - RHD

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.

Brakes
Fig. 49: STOP LAMP SWITCH AND PEDAL CLIP

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. 8. Install the brake tube routing clips with tubes onto the studs on the dash panel.

Brakes
Fig. 50: VACUUM HOSE AT BOOSTER - RHD

9. Connect the vacuum hose (2) to the check valve (1) on the power brake booster.

10. Install the master cylinder.

Brakes
Fig. 51: VACUUM HOSE AT BOOSTER - RHD

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.

Brakes
Fig. 52: MODULE -WIPER

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.

Brakes
Fig. 53: WHEELHOUSE BRACE

15. Install the wheelhouse brace (2). Install and tighten the eight mounting bolts (four each side) (1) to 48 N.m (35 ft. lbs.).

Brakes
Fig. 54: COWL SCREEN

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 90º counterclockwise to lock the screen in place.

17. Install the wiper arms.

Brakes
Fig. 55: COWL TOP SCREEN

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.

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.

    Removal
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