Chrysler PT Cruiser. Manual — part 702
(33) Drain engine oil.
(34) Disconnect the downstream oxygen sensor
connector.
(35) Disconnect exhaust system from manifold
(Fig. 10) or (Fig. 11).
(36) Non-Turbo equipped vehicles: Disconnect
power steering pressure hose from steering gear (Fig.
12).
(37) Turbocharger equipped vehicles: Discon-
nect both power steering hoses from steering gear
(Fig. 13).
Fig. 10 Exhaust System To Manifold Connection
1 - GASKET
2 - CATALYTIC CONVERTER
3 - NUT
Fig. 11 Converter to Exhaust Manifold Connection -
2.4L Turbo
1 - FLAG NUT
2 - GASKET
3 - NUT
4 - BOLT
5 - CATALYTIC CONVERTER
Fig. 12 Power Steering Fluid Pressure Hose
1 - STEERING GEAR
2 - FITTING
3 - POWER STEERING PRESSURE HOSE
Fig. 13 Hoses At Power Steering Gear - 2.4L Turbo
1 - POWER STEERING GEAR
2 - ROUTING CLIP
3 - PRESSURE HOSE TUBE NUT
4 - RETURN HOSE CLAMP
5 - PRESSURE/RETURN HOSE ASSEMBLY
9 - 88
ENGINE 2.4L DOHC
PT
ENGINE 2.4L DOHC (Continued)
(38) Turbocharger equipped vehicles: Remove
upper and lower heat sheilds, elbow support bracket,
turbocharger support bracket, and elbow (Fig. 14).
(39) Remove
structural
collar
(Refer
to
9
-
ENGINE/ENGINE BLOCK/STRUCTURAL COLLAR
- REMOVAL).
(40) Automatic Transmission equipped vehi-
cles:
(a) Remove torque converter bolts and mark con-
verter to flex plate orientation for reassembly.
(41) Manual Transmission equipped vehicles:
(a) Remove drive plate to clutch module bolts.
(42) Remove lower engine torque strut (Refer to 9 -
ENGINE/ENGINE MOUNTING/TORQUE STRUT -
REMOVAL).
(43) Lower vehicle and remove A/C compressor.
(44) Disconnect power steering lines from power
steering pump.
(45) Remove power steering pump.
(46) Raise vehicle enough to allow engine dolly,
cradle, and posts, (Special Tools 6135, 6710, and
6848) to be installed under vehicle. For Special Tool
identification (Refer to 9 - ENGINE - SPECIAL
TOOLS).
(47) Loosen engine support posts to allow move-
ment for positioning onto engine locating holes and
flange on the engine bedplate. Lower vehicle and
position cradle until the engine is resting on support
posts (Fig. 17). Tighten mounts to cradle frame. This
will keep support posts from moving when removing
or installing engine and transmission.
(48) Install safety straps around the engine to cra-
dle (Fig. 17). Tighten straps and lock them into posi-
tion.
WARNING: Safety straps MUST be used.
(49) Raise vehicle enough to determine if straps
are secure enough to hold cradle assembly to engine.
(50) Lower vehicle so weight of the engine and
transmission ONLY is on the cradle assembly.
(51) Remove the upper engine torque strut.
(52)
Remove right mount through bolt (Fig. 15)
and left mount attaching bolts (Fig. 16).
(53) Raise vehicle slowly until engine/transaxle
assembly clears engine compartment. It may be nec-
essary to move the engine/transmission assembly
with the cradle to allow for removal around body
flanges.
Fig. 14 Turbocharger Brackets and Heat Shields
1 - UPPER/LOWER HEAT SHIELDS
2 - TURBOCHARGER SUPPORT BRACKET
3 - ELBOW
4 - ELBOW SUPPORT BRACKET
Fig. 15 Right Mount Through Bolt
1 - BOLT
2 - RIGHT ENGINE MOUNT
3 - ENGINE MOUNT BRACKET
Fig. 16 Left Mount Bolts
1 - BOLT
2 - TRANSAXLE
3 - LEFT MOUNT
PT
ENGINE 2.4L DOHC
9 - 89
ENGINE 2.4L DOHC (Continued)
INSTALLATION - ENGINE ASSEMBLY
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine/transaxle assembly.
(2) Continue lowering vehicle until engine/trans-
axle aligns to mounting locations. Install mounting
bolts at the right and left engine/transaxle mounts
(Fig. 15) and (Fig. 16). Tighten bolts to 118 N·m (87
ft. lbs.).
(3) Install upper engine torque strut.
(4) Remove safety straps from engine/transaxle
assembly. Slowly raise vehicle enough to remove the
engine dolly and cradle.
(5) Install power steering pump.
(6) Connect power steering lines to power steering
pump.
(7) Install A/C compressor.
(8) Install lower engine torque strut (Refer to 9 -
ENGINE/ENGINE MOUNTING/TORQUE STRUT -
INSTALLATION).
(9) Automatic Transmission equipped vehi-
cles:
(a) Install torque converter bolts.
(10) Manual Transmission equipped vehicles:
(a) Install drive plate to clutch module bolts.
(11) Install structural collar (Refer to 9 - ENGINE/
ENGINE
BLOCK/STRUCTURAL
COLLAR
-
INSTALLATION).
(12) Turbocharger equipped vehicles: Install
elbow, turbocharger support bracket, elbow support
bracket, and upper and lower heat shields (Fig. 14).
(13) Non-Turbo
equipped
vehicles:
Connect
power steering pressure hose to steering gear (Fig.
12).
(14) Turbocharger equipped vehicles: Connect
both power steering hoses to steering gear (Fig. 13).
(15) Connect exhaust system to manifold (Fig. 10)
or (Fig. 11).
(16) Connect the downstream oxygen sensor.
(17) Turbocharger equipped vehicles: Install
charge air cooler hoses (Fig. 9).
(18) Install generator and mounting brackets.
(19) Install accessory drive belts (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(20) Install axle shafts (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION).
(21) Install right inner splash shield.
(22) Install wheels and lower vehicle.
(23) Install cooling module assembly (fan, radiator,
A/C condenser, transmission oil cooler). Connect radi-
ator fan electrical connector.
(24) Turbocharger equipped vehicles: Connect
power steering hoses to radiator.
(25) Manual Transmission equipped vehicles:
(a) Connect clutch hydraulic line (Fig. 7).
Fig. 17 Positioning Engine Cradle Support Post
1 - POST LOCATING HOLES IN BLOCK
2 - POST POSITIONED UNDER BRACKET
3 - POST LOCATING HOLE IN STRUT
4 - SAFETY STRAPS
5 - FLOOR JACK
6 - SPECIAL TOOL 6848
7 - SPECIAL TOOL 6135
8 - SPECIAL TOOL 6710
9 - 90
ENGINE 2.4L DOHC
PT
ENGINE 2.4L DOHC (Continued)
(b) Connect transmission shift linkage.
(c) Connect transmission electrical connectors.
NOTE: It is not necessary to bleed the clutch
hydraulic system. The quick-connect fittings close
immediately after disconnection; allowing no fluid
to escape.
(26) Automatic Transmission equipped vehi-
cles:
(a) Connect transmission oil cooler lines using
service splice kit. Refer to instructions provided
with kit.
(b) Connect transmission electrical connectors.
(c) Connect transmission shift linkage.
(27) Connect A/C lines at junction near upper
torque strut.
(28) Connect upper A/C line to A/C condenser.
(29) Install upper and lower radiator hoses.
(30) Install upper radiator closure panel and cen-
ter brace (Refer to 23 - BODY/EXTERIOR/RADIA-
TOR CLOSURE PANEL - INSTALLATION) (Fig. 18).
(31) Install grille (Refer to 23 - BODY/EXTERIOR/
GRILLE - INSTALLATION).
(32) Connect fuel line and heater hoses.
(33) Connect coolant reserve/recovery hose to cool-
ant outlet connector.
(34) Connect brake booster vacuum hose to intake
manifold.
(35) Connect the proportional purge hose to throt-
tle body.
(36) Install all ground straps and connect engine
wiring harness.
(37) Position PDC and install bolts (Fig. 5). Con-
nect positive battery cable to PDC and ground wire
to vehicle body.
(38) Connect engine wiring harness at Powertrain
Control Module (PCM).
(39) Connect throttle and speed control cables.
(40) Install battery tray and battery (Refer to 8 -
ELECTRICAL/BATTERY
SYSTEM/BATTERY
-
INSTALLATION).
(41) Connect cables to battery.
(42) Install air cleaner housing assembly and con-
nect clean air hose (Refer to 9 - ENGINE/AIR
INTAKE
SYSTEM/AIR
CLEANER
HOUSING
-
INSTALLATION).
(43) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(44) Fill power steering system.
(45) Fill cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(46) Evacuate and recharge A/C system (Refer to
24 - HEATING & AIR CONDITIONING - STAN-
DARD PROCEDURE).
(47) Start engine and run until operating temper-
ature is reached.
(48) Perform torque strut adjustment procedure
(Refer
to
9
-
ENGINE/ENGINE
MOUNTING/
TORQUE STRUT - ADJUSTMENTS).
(49) Adjust transmission linkage, if necessary.
Fig. 18 Upper Radiator Closure Panel and Center
Brace
1 - UPPER RADIATOR CLOSURE PANEL
2 - CENTER BRACE
PT
ENGINE 2.4L DOHC
9 - 91
ENGINE 2.4L DOHC (Continued)
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