cable JEEP LIBERTY 2002 KJ / 1.G User Guide

Examine the lining contact pattern to determine if
the shoes are bent or the drum is tapered. The lining
should exhibit contact across its entire width. Shoes
exhibiting contact only on one side should be
replaced and the drum checked for runout or taper.
Inspect the adjuster screw assembly. Replace the
assembly if the star wheel or threads are damaged,
or the components are severely rusted or corroded.
Discard the brake springs and retainer components
if worn, distorted or collapsed. Also replace the
springs if a brake drag condition had occurred. Over-
heating will distort and weaken the springs.
Inspect the brake shoe contact pads on the support
plate, replace the support plate if any of the pads are
worn or rusted through. Also replace the plate if it is
bent or distorted.
(1) Clean support plate with brake cleaner.
(2) If new drums are being installed, remove pro-
tective coating with carburetor cleaner followed by
final rinse with brake cleaner.
(3) Clean and lubricate anchor pin with light coat
of Mopar multi-mileage grease.
(4) Apply Mopar multi-mileage grease to brake
shoe contact surfaces of support plate (Fig. 10).
(5) Lubricate the adjuster screw threads and pivot
with spray lube.
(6) Attach parking brake lever to secondary brake
shoe. Use new washer and U-clip to secure lever.
(7) Attach the parking brake cable to lever (if
removed).
(8) Install the brake shoes on support plate.
Secure shoes with new hold-down springs, pins and
retainers.
(9) Install the parking brake strut and spring.(10) Install the guide plate and adjuster cable on
anchor pin.
(11) Install the adjuster cable guide on the shoe.
(12) Install the primary and secondary return
springs.
(13) Lubricate and assemble adjuster screw.
(14) Install the adjuster screw, spring and lever
and connect to adjuster cable.
(15) Adjust the shoes to the drum (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - ADJUSTMENTS).
(16) Install the brake drum.
(17) Install the wheel/tire assemblies and lower
vehicle (Refer to 22 - TIRES/WHEELS/WHEELS -
STANDARD PROCEDURE).
(18) Verify firm brake pedal before moving vehicle.
ADJUSTMENTS
ADJUSTMENT - REAR DRUM BRAKE
The rear drum brakes are equipped with a self-ad-
justing mechanism. Under normal circumstances, the
only time adjustment is required is when the shoes
are replaced, removed for access to other parts, or
when one or both drums are replaced.
Adjustment can be made with a standard brake
gauge or with adjusting tool. Adjustment is per-
formed with the complete brake assembly installed
on the backing plate.
ADJUSTMENT WITH BRAKE GAUGE
(1) Be sure parking brakes are fully released.
(2) Raise rear of vehicle and remove wheels and
brake drums.
(3) Verify that left and right automatic adjuster
levers and cables are properly connected.
(4) Insert brake gauge in drum. Expand gauge
until gauge inner legs contact drum braking surface.
Then lock gauge in position (Fig. 11).
(5) Reverse gauge and install it on brake shoes.
Position gauge legs at shoe centers as shown (Fig.
12). If gauge does not fit (too loose/too tight), adjust
shoes.
(6) Pull shoe adjuster lever away from adjuster
screw star wheel.
(7) Turn adjuster screw star wheel (by hand) to
expand or retract brake shoes. Continue adjustment
until gauge outside legs are light drag-fit or 30 thou-
sands of an inch clearence on the shoes.
(8) Install brake drums and wheels and lower
vehicle.
(9) Drive vehicle and make one forward stop fol-
lowed by one reverse stop. Repeat procedure 8-10
times to operate automatic adjusters and equalize
adjustment.
Fig. 10 Shoe Contact Surfaces
1 - ANCHOR PIN
2 - SUPPORT PLATE
3 - SHOE CONTACT SURFACES
5 - 12 BRAKES - BASEKJ
BRAKE PADS / SHOES (Continued)

NOTE: Bring vehicle to complete standstill at each
stop. Incomplete, rolling stops will not activate
automatic adjusters.
ADJUSTMENT WITH ADJUSTING TOOL
(1) Be sure parking brake lever is fully released.
(2) Raise vehicle so rear wheels can be rotated
freely.
(3) Remove plug from each access hole in brake
support plates.
(4) Loosen parking brake cable adjustment nut
until there is slack in front cable.
(5) Insert adjusting tool through support plate
access hole and engage tool in teeth of adjusting
screw star wheel (Fig. 13).(6) Rotate adjuster screw star wheel (move tool
handle upward) until slight drag can be felt when
wheel is rotated.
(7) Push and hold adjuster lever away from star
wheel with thin screwdriver.
(8) Back off adjuster screw star wheel until brake
drag is eliminated.
(9) Repeat adjustment at opposite wheel. Be sure
adjustment is equal at both wheels.
(10) Install support plate access hole plugs.
(11) Adjust parking brake cable and lower vehicle.
(12) Drive vehicle and make one forward stop fol-
lowed by one reverse stop. Repeat procedure 8-10
times to operate automatic adjusters and equalize
adjustment.
NOTE: Bring vehicle to complete standstill at each
stop. Incomplete, rolling stops will not activate
automatic adjusters.DISC BRAKE CALIPERS
DESCRIPTION
The calipers are a single piston type. The calipers
are free to slide laterally, this allows continuous com-
pensation for lining wear.
Fig. 11 ADJUSTING GAUGE ON DRUM
1 - BRAKE GAUGE
2 - BRAKE DRUM
Fig. 12 ADJUSTING GAUGE ON BRAKE SHOES
1 - BRAKE GAUGE
2 - BRAKE SHOES
Fig. 13 Brake Adjustment
1 - STAR WHEEL
2 - LEVER
3 - BRAKE SHOE WEB
4 - SCREWDRIVER
5 - ADJUSTING TOOL
6 - ADJUSTER SPRING
KJBRAKES - BASE 5 - 13
BRAKE PADS / SHOES (Continued)

SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications and SAE J1703 standards.
No other type of brake fluid is recommended or
approved for usage in the vehicle brake system. Use
only Mopar brake fluid or an equivalent from a
tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container will absorb moisture from the air
and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would
be items such as engine oil, transmission fluid,
power steering fluid, etc.
DRUM
DIAGNOSIS AND TESTING - BRAKE DRUM
The maximum allowable diameter of the drum
braking surface is indicated on the drum outer edge.
Generally, a drum can be machined to a maximum of
1.52 mm (0.060 in.) oversize. Always replace the
drum if machining would cause drum diameter to
exceed the size limit indicated on the drum.
BRAKE DRUM RUNOUT
Measure drum diameter and runout with an accu-
rate gauge. The most accurate method of measure-
ment involves mounting the drum in a brake lathe
and checking variation and runout with a dial indi-
cator.
Variations in drum diameter should not exceed
0.076 mm (0.003 in.). Drum runout should not exceed
0.20 mm (0.008 in.) out of round. Machine the drum
if runout or variation exceed these values. Replace
the drum if machining causes the drum to exceed the
maximum allowable diameter.
STANDARD PROCEDURES - BRAKE DRUM
MACHINING
The brake drums can be machined on a drum lathe
when necessary. Initial machining cuts should be lim-
ited to 0.12 - 0.20 mm (0.005 - 0.008 in.) at a time as
heavier feed rates can produce taper and surface
variation. Final finish cuts of 0.025 to 0.038 mm(0.001 to 0.0015 in.) are recommended and will gen-
erally provide the best surface finish.
Be sure the drum is securely mounted in the lathe
before machining operations. A damper strap should
always be used around the drum to reduce vibration
and avoid chatter marks.
The maximum allowable diameter of the drum
braking surface is stamped or cast into the drum
outer edge.
CAUTION: Replace the drum if machining will cause
the drum to exceed the maximum allowable diame-
ter.
SUPPORT PLATE
REMOVAL
REMOVAL - 198 RBI AXLE
(1) Remove wheel and tire assembly.
(2) Remove the brake drum.
(3) Remove the brake shoes.
(4) Remove parking brake cable from parking
brake lever.
(5) Compress parking brake cable retainer tabs.
Then push retainer and cable through and out of
support plate.
(6) Disconnect brake line at wheel cylinder.
(7) Remove wheel cylinder from support plate,(Re-
fer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
WHEEL CYLINDERS - REMOVAL).
(8) Remove the four bolts attaching the support
plate to axle and remove the support plate with the
axle, bearing and seal.
(9) Remove axle shaft,(Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/REAR AXLE/AXLE SHAFTS -
REMOVAL).
REMOVAL - 8 1/4 AXLE
(1) Remove the wheel and tire assembly.
(2) Remove the brake drum.
(3) Install the brake pedal prop rod.
(4) Remove the brake shoes (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
- REMOVAL).
(5) Remove parking brake cable from parking
brake lever.
(6) Compress parking brake cable retainer tabs.
Then push retainer and cable through and out of
support plate.
(7) Disconnect the brake line at wheel cylinder.
(8) Remove the wheel cylinder from the support
plate,(Refer to 5 - BRAKES/HYDRAULIC/MECHAN-
ICAL/WHEEL CYLINDERS - REMOVAL).
KJBRAKES - BASE 5 - 27
FLUID (Continued)

(9) Remove the axle shaft, (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/REAR AXLE - 8 1/4/AXLE
SHAFTS - REMOVAL).
(10) Remove the bolts attaching the support plate
to the axle and remove the support plate (Fig. 43).
INSTALLATION
INSTALLATION - 198 RBI AXLE
(1) Install the support plate on the axle flange.
Tighten 75 N´m (55 ft. lbs.)
(2) Install the axle, bearing and seal into the hous-
ing and tighten the four attaching bolts to 61 N´m
(45 ft. lbs.).
(3) Install the wheel cylinder,(Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/WHEEL
CYLINDERS - INSTALLATION).
(4) Install the brake line in the wheel cylinder.
(5) Install the parking brake cable in the support
plate.
(6) Connect parking brake cable to lever on sec-
ondary shoe and install brake shoes on support plate.
(7) Adjust the brake shoes to the drum with the
brake gauge.
(8) Install the brake drum and wheel and tire
assembly (Refer to 22 - TIRES/WHEELS/WHEELS -
STANDARD PROCEDURE).
(9) Bleed brake system,(Refer to 5 - BRAKES -
STANDARD PROCEDURE) OR (Refer to 5 -
BRAKES - STANDARD PROCEDURE).
INSTALLATION - 8 1/4 AXLE
(1) Install the support plate on the axle flange.
Tighten attaching bolts to 61 N´m (45 ft. lbs.) (Fig.
43).(2) Install the wheel cylinder,(Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/WHEEL
CYLINDERS - INSTALLATION).
(3) Install the brake line in the wheel cylinder and
tighten the line to 14 N´m (124 in.lbs.)..
(4) Remove the brake pedal prop rod.
(5) Install the parking brake cable in the support
plate.
(6) Install the axle shaft, (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/REAR AXLE - 8 1/4/AXLE
SHAFTS - INSTALLATION).
(7) Connect the parking brake cable to the lever on
the primary shoe and install the brake shoes on the
support plate (Refer to 5 - BRAKES/HYDRAULIC/
MECHANICAL/BRAKE PADS/SHOES - INSTALLA-
TION).
(8) Adjust the brake shoes to the drum with the
brake gauge (Refer to 5 - BRAKES/HYDRAULIC/
MECHANICAL/BRAKE PADS/SHOES - ADJUST-
MENTS).
(9) Install the brake drum.
(10) Install the wheel and tire assembly (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(11) Bleed the brake system,(Refer to 5 - BRAKES
- STANDARD PROCEDURE).
WHEEL CYLINDERS
REMOVAL
(1) Remove wheel and tire assembly.
(2) Remove brake drum.
(3) Install brake pedal prop rod.
(4) Disconnect wheel cylinder brake line.
(5) Remove brake shoe return springs and move
shoes out of engagement with cylinder push rods.
(6) Remove cylinder attaching bolts and remove
cylinder from support plate (Fig. 44).
DISASSEMBLY
(1) Remove push rods and boots (Fig. 45).
(2) Press pistons, cups and spring and expander
out of cylinder bore.
(3) Remove bleed screw.
CLEANING
Clean the cylinder and pistons with clean brake
fluid or brake cleaner only. Do not use any other
cleaning agents.
Dry the cylinder and pistons with compressed air.
Do not use rags or shop towels to dry the cylinder
components. Lint from cloth material will adhere to
the cylinder bores and pistons.
Fig. 43 SUPPORT PLATE 8 1/4
1 - SUPPORT PLATE
2 - MOUNTING NUTS
5 - 28 BRAKES - BASEKJ
SUPPORT PLATE (Continued)

INSPECTION
Inspect the cylinder bore. Light discoloration and
dark stains in the bore are normal and will not
impair cylinder operation.
The cylinder bore can be lightly polished but only
with crocus cloth. Replace the cylinder if the bore is
scored, pitted or heavily corroded. Honing the bore to
restore the surface is not recommended.
Inspect the cylinder pistons. The piston surfaces
should be smooth and free of scratches, scoring and
corrosion. Replace the pistons if worn, scored, or cor-
roded. Do not attempt to restore the surface by sand-
ing or polishing.Discard the old piston cups and the spring and
expander. These parts are not reusable. The original
dust boots may be reused but only if they are in good
condition.
ASSEMBLY
(1) Lubricate wheel cylinder bore, pistons, piston
cups and spring and expander with clean brake fluid.
(2) Install first piston in cylinder bore. Then
install first cup in bore and against piston.Be sure
lip of piston cup is facing inward (toward
spring and expander) and flat side is against
piston.
(3) Install spring and expander followed by
remaining piston cup and piston.
(4) Install boots on each end of cylinder and insert
push rods in boots.
(5) Install cylinder bleed screw.
INSTALLATION
(1) Install cylinder mounting bolts and tighten to
20 N´m (15 ft. lbs.) (Fig. 44).
(2) Connect brake line to cylinder and tighten to
14 N´m (124 in. lbs.).
(3) Install the brake shoe return springs.
(4) Remove the brake pedal prop rod.
(5) Install the brake drum.
(6) Install the wheel and tire assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(7) Bleed base brake system (Refer to 5 - BRAKES
- STANDARD PROCEDURE).
PARKING BRAKE
DESCRIPTION
The parking brake is a hand lever and cable oper-
ated system used to apply the rear brakes.
OPERATION
A hand operated lever in the passenger compart-
ment is the main application device. The front cable
is connected between the hand lever and the rear
cables with an equalizer.
The rear cables are connected to the actuating
lever on each primary brake shoe. The levers are
attached to the brake shoes by a pin either pressed
into, or welded to the lever. A clip is used to secure
the pin in the brake shoe. The pin allows each lever
to pivot independently of the brake shoe.
To apply the parking brakes, the hand lever is
pulled upward. This pulls the rear brake shoe actu-
ating levers forward, by means tensioner and cables.
As the actuating lever is pulled forward, the parking
brake strut (which is connected to both shoes), exerts
Fig. 44 WHEEL CYLINDER
1 - WHEEL CYLINDER
2 - SUPPORT PLATE
Fig. 45 Wheel Cylinder Components±Typical
1 - SPRING
2 - CYLINDER
3 - PISTON CLIP
4 - BOOT
5 - PUSH ROD
6 - PISTON
7 - BLEED SCREW
8 - CUP EXPANDERS
KJBRAKES - BASE 5 - 29
WHEEL CYLINDERS (Continued)

a linear force against the secondary brake shoe. This
action presses the secondary shoe into contact with
the drum. Once the secondary shoe contacts the
drum, force is exerted through the strut. This force is
transferred through the strut to the primary brake
shoe causing it to pivot into the drum as well.
A gear type ratcheting mechanism is used to hold
the lever in an applied position. Parking brake
release is accomplished by the hand lever release
button.
A parking brake switch is mounted on the parking
brake lever and is actuated by movement of the
lever. The switch, which is in circuit with the red
warning light in the dash, will illuminate the warn-
ing light whenever the parking brakes are applied.
Parking brake is self-adjusting when the lever is
pulled. The cable tensioner, once adjusted at the fac-
tory, should not need further adjustment under nor-
mal circumstances.
ADJUSTMENTS
ADJUSTMENT - LOCK OUT
NOTE: The parking brake is self-adjusting, It can
not be adjusted.
(1) Remove the center floor console (Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE - REMOVAL).
(2) Pull up on the spring until the tab on the lever
passes the tab on the cable guide and install a punch
in the hole on the side then release (Fig. 46).(3) The park brake system is now locked out to
perform necessary repairs.
CABLES
REMOVAL
(1) Lock out the parking brake cables (Refer to 5 -
BRAKES/PARKING BRAKE - ADJUSTMENTS) (Fig.
46).
(2) Remove the rear seat (Refer to 23 - BODY/
SEATS/SEAT - REMOVAL).
(3) Remove the cable saddle bracket (Fig. 47).
(4) Disconnect the two cables from the front mount
(Fig. 48).
(5) Pull the carpet forward far enough in the rear
to gain access to the two parking brake cables thru
the floor (Fig. 47).
(6) Push the cables thru the floor with the grom-
mets.
(7) Remove the primary brake shoe hold down
spring and separate the shoes to gain access, Then
disconnect the cable from lever on brake shoe.
(8) Remove cables from backing plates by using a
screw driver to break off the tangs on the cable or a
proper sized box end wrench over the tangs.
INSTALLATION
(1) Install the cables into the support plate.
(2) Reconnect the cable to the lever on the brake
shoe, Install the primary brake shoe hold down
spring and the shoes.
Fig. 46 LOCK OUT CABLES
1 - PARKING BRAKE HANDLE
2 - PUNCH
3 - CABLE GUIDE
4 - CABLE
Fig. 47 MOUNTING BRACKETS
1 - MOUNTING SADDLE BRACKET
2 - PARK BRAKE CABLES
3 - CARPET
5 - 30 BRAKES - BASEKJ
PARKING BRAKE (Continued)

(3) Push the cables thru the floor and seat the
grommets.
(4) Reconnect the two cables to the front mount.
(5) Install the cable saddle bracket (Fig. 47).
(6) Lay the carpet back down in the rear.
(7) Install the rear seat (Refer to 23 - BODY/
SEATS/SEAT - INSTALLATION).
(8) Remove the lock out device on the lever.
(9) Test the parking brake.
LEVER
REMOVAL
The center floor console must be removed to service
the parking brake lever,(Refer to 23 - BODY/INTERI-
OR/FLOOR CONSOLE - REMOVAL) .
(1) Lock out the parking brakes (Refer to 5 -
BRAKES/PARKING BRAKE - ADJUSTMENTS).
(2) Disengage the front cables from the equalizer
(Fig. 49).
(3) Disconnect the parking brake lamp switch wire
(Fig. 49).
(4) Remove the parking brake lever assembly
mounting bolts (Fig. 50).
(5) Remove the lever assembly.
INSTALLATION
(1) Install the parking brake lever assembly.
(2) Install the parking brake lever assembly to the
mounting bolts. Tighten (Fig. 50).
Install the center floor console, (Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE - INSTALLA-
TION).
(3) Engage the front cables to the equalizer (Fig.
49).(4) Reconnect the parking brake lamp switch wire
(Fig. 49).
(5) If installing a new parking brake lever remove
the pin that come on the lever when shipped.
(6) If you are reinstalling the original park brake
lever remove the lock out device at this time.
(7) Test the parking brake lever. (Fig. 50).
Fig. 48 CABLE FRONT MOUNT
1 - RETAINER CLIPS
2 - CABLES
Fig. 49 PARKING BRAKE LEVER
1 - PARK BRAKE LEVER ASSEMBLY
2 - EQUALIZER
Fig. 50 LEVER MOUNT
1 - ELECTRICAL CONNECTOR
2 - PARK BRAKE LEVER ASSEMBLY
3 - CABLE
KJBRAKES - BASE 5 - 31
CABLES (Continued)

REMOVAL
(1) Install prop rod on the brake pedal to keep
pressure on the brake system.
(2) Remove negative battery cable from the bat-
tery.
(3) Pull up on the CAB harness connector release
(Fig. 3)and remove connector.
(4) Remove brake lines from the HCU.
(5) Remove HCU/CAB mounting nuts and bolt
(Fig. 4) and remove HCU/CAB.
INSTALLATION
(1) Install HCU/CAB on the mounting studs.
(2) Install mounting nuts and bolt. Tighten to 11.5
N´m (102 in. lbs.).
(3) Install brake lines to the HCU and tighten to
19 N´m (170 in. lbs.).
(4) Install wiring harness connector to the CAB
and push down on the release to secure the connec-
tor.
(5) Install negative battery cable to the battery.
(6) Bleed ABS brake system (Refer to 5 - BRAKES
- STANDARD PROCEDURE).Fig. 3 CAB HARNESS CONNECTOR RELEASE
1 - ABS MODULE
2 - ELECTRICAL CONNECTOR
Fig. 4 HCU/CAB MOUNTING
1 - HCU
2 - CAB
3 - HCU/CAB BRACKET
4 - MOUNTING NUTS AND STUDS
5 - MOTOR
5 - 36 BRAKES - ABSKJ
HCU (HYDRAULIC CONTROL UNIT) (Continued)

On a Dual Mass Flywheel the additional secondary
mass coupled to the transmission lowers the natural
frequency of the transmission rotating elements. This
decreases the transmission gear rattle. The damper
springs between the two flywheel masses replace the
clutch disc damper springs and assist in a smooth
transfer of torque to the transmission.
CAUTION: The Dual Mass Flywheel is serviced as
an assembly only and should never be taken apart.
DIAGNOSIS AND TESTING - FLYWHEEL
Check flywheel runout whenever misalignment is
suspected. Flywheel runout should not exceed 0.08
mm (0.003 in.). Measure runout at the outer edge of
the flywheel face with a dial indicator. Mount the
indicator on a stud installed in place of one of the fly-
wheel bolts.
Common causes of runout are:
²heat warpage
²improper machining
²incorrect bolt tightening
²improper seating on crankshaft flange shoulder
²foreign material on crankshaft flange
Flywheel machining is not recommended. The fly-
wheel clutch surface is machined to a unique contour
and machining will negate this feature. Minor fly-
wheel scoring can be cleaned up by hand with 180
grit emery or with surface grinding equipment.
Remove only enough material to reduce scoring
(approximately 0.001 - 0.003 in.). Heavy stock
removal isnot recommended.Replace the flywheel
if scoring is severe and deeper than 0.076 mm (0.003
in.). Excessive stock removal can result in flywheel
cracking or warpage after installation; it can also
weaken the flywheel and interfere with proper clutch
release.
Clean the crankshaft flange before mounting the
flywheel. Dirt and grease on the flange surface may
cock the flywheel causing excessive runout. Use new
bolts when remounting a flywheel and secure the
bolts with Mopar Lock And Seal or equivalent.
Tighten flywheel bolts to specified torque only. Over-
tightening can distort the flywheel hub causing
runout.
PILOT BEARING
REMOVAL
(1) Remove the transmission.
(2) Remove pressure plate and clutch disc.
(3) Remove pilot bearing with an internal (blind
hole) puller.
INSTALLATION
(1) Lubricate new bearing with Mopar high tem-
perature bearing grease or equivalent.
(2) Start new bearing into crankshaft by hand.
Then seat bearing with clutch alignment tool (Fig. 5).
(3) Lightly scuff sand flywheel surface with 180
grit emery cloth. Then clean surface with wax and
grease remover.
(4) Install clutch disc and pressure plate.
(5) Install the transmission.
LINKAGE
REMOVAL
NOTE: The clutch master cylinder, slave cylinder
and connecting line are serviced as an assembly
only. The linkage components cannot be over-
hauled or serviced separately. The cylinders and
connecting line are sealed units.
(1) Raise vehicle.
(2) Remove fasteners attaching slave cylinder to
clutch housing.
(3) Remove slave cylinder from clutch housing
(Fig. 6).
(4) Disengage clutch fluid line from body clips, if
applicable.
(5) Lower vehicle.
(6) Verify cap on clutch master cylinder reservoir
is tight to avoid spilling fluid during removal.
(7) Remove clutch master cylinder attaching nuts
(Fig. 7).
(8) Disengage captured bushing on clutch master
cylinder actuator from pivot pin on pedal arm.
Fig. 5 Pilot Bearing Installer
1 - PILOT BEARING
2 - ALIGNMENT TOOL
6 - 8 CLUTCHKJ
FLYWHEEL (Continued)

the pan, it will drain first because it is heavier than
oil. An alternative method is to operate engine for a
short period to churn the oil. After this is done,
remove engine dipstick and inspect for water glob-
ules. Also inspect transmission dipstick for water
globules and transmission fluid cooler for leakage.
WARNING: WITH RADIATOR PRESSURE TESTER
TOOL INSTALLED ON RADIATOR, DO NOT ALLOW
PRESSURE TO EXCEED 124 KPA (18 PSI). PRES-
SURE WILL BUILD UP QUICKLY IF A COMBUSTION
LEAK IS PRESENT. TO RELEASE PRESSURE,
ROCK TESTER FROM SIDE TO SIDE. WHEN
REMOVING TESTER, DO NOT TURN TESTER MORE
THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE.
Operate engine without pressure cap on radiator
until thermostat opens. Attach a Pressure Tester to
filler neck. If pressure builds up quickly it indicates a
combustion leak exists. This is usually the result of a
cylinder head gasket leak or crack in engine. Repair
as necessary.
If there is not an immediate pressure increase,
pump the Pressure Tester. Do this until indicated
pressure is within system range of 110 kPa (16 psi).
Fluctuation of gauge pointer indicates compression or
combustion leakage into cooling system.
Because the vehicle is equipped with a catalytic
converter,do notremove spark plug cables or short
out cylinders to isolate compression leak.
If the needle on dial of pressure tester does not
fluctuate, race engine a few times to check for an
abnormal amount of coolant or steam. This would be
emitting from exhaust pipe. Coolant or steam from
exhaust pipe may indicate a faulty cylinder head gas-
ket, cracked engine cylinder block or cylinder head.A convenient check for exhaust gas leakage into
cooling system is provided by a commercially avail-
able Block Leak Check tool. Follow manufacturers
instructions when using this product.
COMBUSTION LEAKAGE TEST - WITHOUT
PRESSURE TESTER
DO NOT WASTE reusable coolant. If solution is
clean, drain coolant into a clean container for reuse.
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Drain sufficient coolant to allow thermostat
removal. (Refer to 7 - COOLING/ENGINE/ENGINE
COOLANT THERMOSTAT - REMOVAL). Remove
accessory drive belt (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - REMOVAL).
Add coolant to radiator to bring level to within 6.3
mm (1/4 in) of top of thermostat housing.
CAUTION: Avoid overheating. Do not operate
engine for an excessive period of time. Open drain-
cock immediately after test to eliminate boil over.
Start engine and accelerate rapidly three times, to
approximately 3000 rpm while observing coolant. If
internal engine combustion gases are leaking into
cooling system, bubbles will appear in coolant. If bub-
bles do not appear, internal combustion gas leakage
is not present.
KJCOOLING 7 - 5
COOLING (Continued)