Chrysler PT Cruiser. Manual — part 728
OIL RETURN LINE
(1) Raise vehicle on hoist.
(2) Remove the two fasteners securing the oil
return line to the turbocharger.
(3) Remove hose clamp from oil return line.
(4) Remove oil return line from crankcase nipple
(Fig. 37).
INSTALLATION - LINES AND HOSES
NOTE: For line and hose location refer to (Fig. 37).
COOLANT SUPPLY LINE
(1) If brass fitting was removed from engine block,
apply thread sealer to threads and install in engine
block. Torque brass fitting to 41 N·m (30 ft. lbs.).
(2) Position coolant supply line to mounting loca-
tion.
(3) Install NEW washers on banjo fitting of cool-
ant supply line (Fig. 44). Hand start banjo bolt.
(4) Hand start flared fitting of coolant supply line.
(5) Torque banjo fitting bolt to 30 N·m (22 ft. lbs.)
(Fig. 38).
(6) Torque flared fitting to 31 N·m (23 ft. lbs.) (Fig.
39).
(7) Lower vehicle.
(8) Fill cooling system (Refer to 7 - COOLING/EN-
GINE - STANDARD PROCEDURE).
COOLANT RETURN LINE
(1) Position coolant return line to mounting loca-
tion.
(2) Install NEW washers on banjo fitting of cool-
ant return line (Fig. 44). Hand start banjo bolt.
(3) Install hose onto heater tube. Install hose
clamp (Fig. 40).
(4) Torque banjo fitting bolt to 30 N·m (22 ft. lbs.)
(Fig. 38).
(5) Install fastener securing coolant return line
bracket to cylinder head cover stud (Fig. 40).
(6) Connect charge air cooler hose to throttle body.
(7) Tighten hose clamp to 1.7 N·m (15 in. lbs.).
(8) Connect Throttle Inlet Pressure (TIP) hose to
charge air cooler hose (Fig. 32).
(9) Connect Inlet Air Temperature (IAT) sensor
connector (Fig. 32).
(10) Install air cleaner housing (Refer to 9 -
ENGINE/AIR
INTAKE
SYSTEM/AIR
CLEANER
HOUSING - INSTALLATION).
(11) Fill cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
OIL SUPPLY LINE
(1) If brass fitting was removed from engine block
or turbocharger, apply thread sealer to threads and
install. Torque brass fitting to 41 N·m (30 ft. lbs.).
(2) Position oil supply line to mounting location.
(3) Hand start flared fitting at turbocharger (Fig.
43).
(4) Raise vehicle on hoist.
(5) Hand start flared fitting at engine block (Fig.
42).
(6) Torque flared fittings to 31 N·m (23 ft. lbs.)
(Fig. 42) and (Fig. 43).
(7) Install elbow support bracket (Fig. 41).
(8) Lower vehicle.
OIL RETURN LINE
(1) Clean gasket surfaces.
(2) Install new gasket.
(3) Install oil return line hose over crankcase nip-
ple (Fig. 37).
(4) Install the two fasteners securing the oil return
line to the turbocharger. Torque fasteners to 12 N·m
(105 in. lbs.).
(5) Install hose clamp for oil return line hose.
(6) Lower vehicle.
Fig. 44 Banjo Bolt and Washers
1 - BANJO BOLT
2 - WASHERS
11 - 26
EXHAUST SYSTEM AND TURBOCHARGER
PT
LINES AND HOSES (Continued)
SOLENOIDS AND VACUUM
HARNESS
DESCRIPTION
NOTE: Refer to (Fig. 45) and (Fig. 46) for compo-
nent location and vacuum harness routing.
Turbocharged vehicles are equipped with three
solenoids that are PCM controlled. They are mounted
to the right shock tower. A vacuum harness connects
the solenoids to their respective component.
• Wastegate Actuator Solenoid
• Surge Valve Actuator Solenoid
• Throttle Inlet Pressure (TIP) Solenoid
REMOVAL
NOTE: For specific solenoid location, refer to (Fig.
46).
(1) Remove
nuts
securing
solenoid
mounting
bracket to shock tower (Fig. 47).
(2) Disconnect solenoid electrical connector.
Fig. 45 Vacuum Harness Schematic
Fig. 46 Turbocharger Solenoids
1 - SPEED CONTROL SERVO
2 - TIP SENSOR
3 - WASTEGATE ACTUATOR SOLENOID
4 - SURGE VALVE ACTUATOR SOLENOID
5 - TIP SOLENOID
PT
EXHAUST SYSTEM AND TURBOCHARGER
11 - 27
(3) Disconnect vacuum harness connector from
solenoid.
(4) Push on solenoid lock tab and slide solenoid off
bracket (Fig. 48).
INSTALLATION
(1) Slide solenoid onto mounting bracket until lock
tab engages (Fig. 48).
(2) Connect vacuum harness connector to solenoid.
(3) Connect solenoid electrical connector.
(4) Install
nuts
securing
solenoid
mounting
bracket to shock tower (Fig. 47).
Fig. 48 Solenoid Lock Tab
1 - LOCK TAB
Fig. 47 Solenoid Mounting Bracket
1 - NUTS
11 - 28
EXHAUST SYSTEM AND TURBOCHARGER
PT
SOLENOIDS AND VACUUM HARNESS (Continued)
FRAME & BUMPERS
TABLE OF CONTENTS
page
page
BUMPERS
FRONT BUMPER REINFORCEMENT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . 2
FRONT BUMPER FASCIA
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . 4
REAR BUMPER FASCIA
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . 5
REAR BUMPER REINFORCEMENT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . . . . . . . 6
FRAME
SPECIFICATIONS - FRAME DIMENSIONS
FRONT CROSSMEMBER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . . . . . . . . . . . . . . . . . . . . . . . 14
FRONT EMERGENCY TOW EYE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . . . . . . . . . . . . . . . . . . . 16
REAR EMERGENCY TOW EYE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . . . . . . . . . . . . . . . . . . . 16
SIDE RAIL TIE DOWN BRACKET
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
. . . . . . . . . . . . . . . . . . . . . . . . . 17
BUMPERS
SPECIFICATIONS - TIGHTENING
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Front bumper reinforcement to rail attaching bolt
25
—
225
Front bumper reinforcement to side of rail attaching bolt
25
—
225
Front fascia to fender bracket assembly attaching screws
2
—
24
Front fascia to upper crossmember bracket attaching screws
5
—
43
Splash shield to front fascia attaching screw
2
—
24
Lower front fascia bracket to lower radiator crossmember attaching
screws
6
—
50
Front fascia to fender screws
6
—
50
Air dam to front fascia attaching screw
2
—
24
Air dam to lower crossmember bracket attaching screws
2
—
24
Grille to fender attaching screw
2
—
24
Grille to crossmember attaching screw
2
—
24
Rear bumper reinforcement attaching screw
25
—
225
Rear fascia to fender attaching screw
2
—
24
Splash shield to rear fascia attaching screw
27
20
—
Rear fascia stud plate to rear closure attaching nuts
6
—
50
PT
FRAME & BUMPERS
13 - 1
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