Chrysler PT Cruiser. Manual — part 463

INSTALLATION

(1) Place the new thermostat assembly into the

coolant outlet connector, aligning air bleed with the
location notch on outlet connector (Fig. 25).

(2) Install coolant outlet connector with thermostat

in position onto thermostat housing (Fig. 23). Tighten
bolts to 12.5 N·m (110 in. lbs.).

(3) Turbocharger equipped vehicles:
• Attach A/C suction line support bracket to A/C

suction line.

• Install fastener securing A/C suction line sup-

port bracket to coolant oulet connector.

(4) Connect upper radiator hose.
(5) Connect the coolant recovery system hose.
(6) Install upper intake manifold (Refer to 9 -

ENGINE/MANIFOLDS/INTAKE

MANIFOLD

-

INSTALLATION).

(7) Fill cooling system (Refer to 7 - COOLING/EN-

GINE - STANDARD PROCEDURE).

HOSE CLAMPS

DESCRIPTION - HOSE CLAMPS

The cooling system utilizes both worm drive and

spring type hose clamps. If a spring type clamp

replacement is necessary, replace with the original
Mopar

t equipment spring type clamp.

CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 26).

OPERATION

The worm type hose clamp uses a specified torque

value to maintain proper tension on a hose connection.

The spring type hose clamp applies constant ten-

sion on a hose connection. To remove a spring type
hose clamp, only use constant tension clamp pliers
(Special Tool 8495) designed to compress the hose
clamp. For Special Tool Identification, (Refer to 7 -
COOLING - SPECIAL TOOLS).

RADIATOR FAN

DESCRIPTION

Non-Turbo

The radiator cooling fan is a dual-speed electric motor

driven fan. The radiator fan assembly includes an elec-
tric motor, fan blade, and a support shroud that is
attached to the radiator (Fig. 31). The radiator fan is
serviced as an assembly (fan motor/fan/shroud).

Turbo

The radiator cooling fan is a variable speed electric

motor driven fan. The radiator fan assembly includes
an electric motor, fan blade, and a support shroud
that is attached to the radiator (Fig. 32). The radia-
tor fan is serviced as an assembly (fan motor/fan/
shroud).

Fig. 25 Thermostat Position

1 - LOCATOR NOTCH
2 - AIR BLEED

Fig. 26 Spring Clamp Size Location

1 - SPRING CLAMP SIZE LOCATION

7 - 54

ENGINE - 2.0/2.4L DOHC

PT

ENGINE COOLANT THERMOSTAT (Continued)

OPERATION

Non-Turbo

Radiator fan operation is control by the Powertrain

Control Module (PCM) with inputs from the temper-
ature of the coolant, which is sensed by the coolant
temperature sensor, and vehicle speed which is mea-
sured by the vehicle speed sensor. The PCM turns on
the fan through either the high or low speed fan
relay. The PCM provides a ground to the relay’s con-
trol circuit. The fan relays are located in the Power
Distribution Center (PDC) (Fig. 27). Refer to the
label beneath the PDC cover for location of fan
relays.

Refer to Radiator Fan Operation Chart for fan

operation specifications. For fan circuit wiring dia-
grams, refer to WIRING DIAGRAMS.

If the cooling fan is inoperative or a Diagnostic

Trouble Code (DTC) related to fan control has been
set, refer to the appropriate Powertrain Diagnostic
Information for diagnostic procedures.

RADIATOR FAN OPERATION CHART

Radiator Fan Control

Low Speed

High Speed

A/C Off –vehicle speed < 70.8 km/h (44 mph)

Fan On:

96.6° C (206°

F)

103° C (219° F)

Fan Off:

92.7° C (199°

F)

98.8° C (210°

F)

A/C Off –vehicle speed > 70.8 km/h (44 mph) (until
vehicle speed drops below 58 km/h (36 mph)

Fan On:

Off

103° C (219° F)

Fan Off:

98.8° C (210°

F)

A/C On –any vehicle speed

Fan On:

Off

82.2° C (180°

F)

Fan Off:

80° C (176° F)

Turbo

The variable speed radiator fan is controlled by the

Powertrain Control Module (PCM) by way of a Pulse
Width Modulated (PWM) signal. The duty cycle
ranges from 30% for low speed operation, then
ramps-up to 100% for high speed operation. This fan
control

system

provides

infinitely

variable

fan

speeds, allowing for improved fan noise, A/C perfor-
mance, better engine cooling, and additional vehicle
power.

To control radiator fan operation, the PCM looks at

inputs from:

• Engine coolant temperature

• A/C pressure transducer

• Ambient temperature

• Vehicle speed

• Transmission oil temperature (automatic trans-

mission only)

The PCM uses these inputs to determine when the

fan should operate and at what speed.

Fig. 27 Power Distribution Center (PDC)

1 - PCM
2 - PDC

PT

ENGINE - 2.0/2.4L DOHC

7 - 55

RADIATOR FAN (Continued)

DIAGNOSIS AND TESTING

RADIATOR FAN MOTOR TEST

Refer to Powertrain Diagnostic Manual for proce-

dure.

REMOVAL

NOTE: The fan motor, fan, and the shroud are ser-
viced as an assembly.

WARNING: DO NOT OPEN THE RADIATOR DRAIN-
COCK WITH THE SYSTEM HOT AND UNDER PRES-
SURE

BECAUSE

SERIOUS

BURNS

FROM

COOLANT CAN OCCUR.

(1) Disconnect negative cable from battery.
(2) Remove battery and battery tray (Refer to 8 -

ELECTRICAL/BATTERY

SYSTEM/BATTERY

-

REMOVAL).

(3) Drain cooling system below upper radiator hose

level (Refer to 7 - COOLING/ENGINE - STANDARD
PROCEDURE).

(4) Remove grille (Refer to 23 - BODY/EXTERIOR/

GRILLE - REMOVAL).

(5) Remove upper radiator closure panel and cen-

ter brace (Refer to 23 - BODY/EXTERIOR/RADIA-
TOR CLOSURE PANEL - REMOVAL) (Fig. 28).

(6) Disconnect upper radiator hose from radiator.
(7) Turbocharger equipped vehicles: Remove

radiator inlet neck (Fig. 29).

(8) Hoist vehicle.
(9) Disconnect radiator fan electrical connector

(Fig. 30).

(10) Remove the two lower and left side radiator

fan screws (Fig. 31) and (Fig. 32).

(11) Lower vehicle and remove the remaining radi-

ator fan attaching screws.

CAUTION: Care should be taken not to damage the
radiator cooling fins and tubes during fan removal.

Fig. 28 Upper Radiator Closure Panel and Center

Brace

1 - UPPER RADIATOR CLOSURE PANEL
2 - CENTER BRACE

Fig. 29 Radiator Inlet Neck - 2.4L Turbo

1 - FASTENERS
2 - RADIATOR INLET NECK

Fig. 30 Radiator Fan Connector - 2.4L Turbo

1 - RADIATOR FAN CONNECTOR
2 - RADIATOR DRAINCOCK

7 - 56

ENGINE - 2.0/2.4L DOHC

PT

RADIATOR FAN (Continued)

(12) Remove radiator fan by lifting up from the

engine compartment.

INSTALLATION

(1) Install the radiator fan into position on the

radiator.

(2) Hand start all radiator fan fasteners.
(3) Tighten all radiator fan retaining screws to 6

N·m (55 in. lbs.) (Fig. 31) and (Fig. 32).

(4) Connect radiator fan electrical connector (Fig.

30).

(5) Lower vehicle.
(6) Turbocharger equipped vehicles: Inspect

radiator inlet neck o-ring. Replace if necessary.
Install radiator inlet neck (Fig. 29). Torque fasteners
to 6 N·m (55 in. lbs.).

(7) Connect the upper radiator hose to radiator.

Align hose and position clamp so it will not interfere
with the engine or the hood.

(8) Install upper radiator closure panel and center

brace (Refer to 23 - BODY/EXTERIOR/RADIATOR
CLOSURE PANEL - INSTALLATION) (Fig. 28).

(9) Install grille (Refer to 23 - BODY/EXTERIOR/

GRILLE - INSTALLATION).

(10) Install battery tray and battery.
(11) Connect cables to battery.
(12) Fill cooling system (Refer to 7 - COOLING/

ENGINE - STANDARD PROCEDURE).

RADIATOR

REMOVAL

WARNING: DO NOT OPEN THE RADIATOR DRAIN-
COCK WITH THE SYSTEM HOT AND UNDER PRES-
SURE

BECAUSE

SERIOUS

BURNS

FROM

COOLANT CAN OCCUR.

NOTE: It is not necessary to discharge the air con-
ditioning system to remove the radiator.

(1) Drain cooling system (Refer to 7 - COOLING/

ENGINE - STANDARD PROCEDURE).

(2) Remove radiator fan (Refer to 7 - COOLING/

ENGINE/RADIATOR FAN - REMOVAL).

(3) Turbocharger Equipped Vehicles: Discon-

nect and cap the power steering hoses.

(4) Disconnect lower radiator hose (Fig. 33).
(5) Non-Turbo Vehicles with Automatic Trans-

mission: Remove two fasteners attaching transmis-
sion oil cooler to radiator.

(6) Non-Turbo Vehicles: Dislodge lower radiator

air seal from side radiator air seals (Fig. 34).

(7) Remove fasteners attaching AC condenser to

radiator. Reposition AC condenser.

(8) Turbocharger Equipped Vehicles: Remove

fasteners attaching charge air cooler to radiator (Fig.
35).

Fig. 31 Radiator Fan - Mounting

1 - RADIATOR FAN SHROUD
2 - SCREWS
3 - SCREWS

Fig. 32 Cooling Module - 2.4L Turbo

1 - RADIATOR FAN FASTENERS
2 - CHARGE AIR COOLER FASTENERS
3 - RADIATOR FAN CONNECTOR
4 - CHARGE AIR COOLER

PT

ENGINE - 2.0/2.4L DOHC

7 - 57

RADIATOR FAN (Continued)