Chrysler PT Cruiser. Manual — part 454
COOLANT
DESCRIPTION
CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less corrosion protection. Do not
mix coolant types. If coolant other than Mopar
T
Antifreeze/Coolant, 5 Year/100,000 Mile Formula or
equivalent is added, the mixed coolant will have a
reduced service schedule.
The use of aluminum cylinder heads, and water
pumps requires special corrosion protection. Mopar
t
Antifreeze/Coolant, 5 Year/100,000 Mile Formula or
equivalent ethylene glycol based coolant with corro-
sion inhibitors (called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% Ethylene Glycol and 50% distilled
water to obtain a freeze point of -37°C (-35°F). If it
loses color or becomes contaminated, drain, flush,
and replace with fresh properly mixed coolant solu-
tion. Mixing of coolants other than specified (non-
HOAT), will reduce the 5 year/100,000 mile corrosion
protection.
DIAGNOSIS AND TESTING - COOLANT
CONCENTRATION TESTING
Coolant concentration should be checked when any
additional coolant was added to system or after a
coolant drain, flush and refill. The coolant mixture
offers optimum engine cooling and protection against
corrosion when mixed to a freeze point of -37°C
(-34°F) to -46°C (-50°F). The use of a hydrometer or a
refractometer can be used to test coolant concentra-
tion.
A hydrometer will test the amount of glycol in a
mixture by measuring the specific gravity of the mix-
ture. The higher the concentration of ethylene glycol,
the larger the number of balls that will float, and
higher the freeze protection (up to a maximum of
60% by volume glycol).
A refractometer (Special Tool 8286)(Refer to 7 -
COOLING - SPECIAL TOOLS) will test the amount
of glycol in a coolant mixture by measuring the
amount a beam of light bends as it passes through
the fluid.
Some coolant manufactures use other types of gly-
cols into their coolant formulations. Propylene glycol
is the most common new coolant. However, propylene
glycol based coolants do not provide the same freez-
ing protection and corrosion protection and is not rec-
ommended.
CAUTION: Do not mix types of coolant—corrosion
protection will be severely reduced.
STANDARD PROCEDURE
STANDARD PROCEDURE - COOLANT SERVICE
For engine coolant recommended service schedule,
(Refer to LUBRICATION & MAINTENANCE/MAIN-
TENANCE SCHEDULES - DESCRIPTION).
STANDARD PROCEDURE - ROUTINE COOLANT
LEVEL CHECK
NOTE: Do not remove pressure cap for routine
coolant level inspections.
The coolant recovery/reserve system provides a
quick visual method for determining the coolant level
without removing the radiator cap. Simply observe,
with the engine idling and warmed up to normal
operating temperature, that the level of the coolant
in the recovery/reserve container is between the
FULL HOT and ADD marks (Fig. 6).
Fig. 6 Coolant Level
1 - COOLANT RECOVERY CONTAINER
7 - 18
ENGINE - 1.6L SOHC
PT
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
NOTE: The radiator cap should not be removed.
NOTE: If the cooling system is completely empty,
(Refer to 7 - COOLING/ENGINE - STANDARD PRO-
CEDURE - FILLING COOLING SYSTEM).
When additional coolant is needed, it should be
added to the coolant recovery container. Use only a
50/50 concentration of the recommended ethylene
glycol type antifreeze and distilled water. (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
HOSE CLAMPS
DESCRIPTION - HOSE CLAMPS
The cooling system uses 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. 7).
The spring type hose clamp applies constant ten-
sion on a hose connection. To remove a spring type
hose clamp, use Special Tool 6094 or 8495 (or equiv-
alent), constant tension clamp pliers (Fig. 8) to com-
press the hose clamp.
COOLANT RECOVERY
CONTAINER
DESCRIPTION
The coolant recovery system consists of a coolant
recovery container mounted to the dash panel, a vent
hose for the coolant recovery container, a hose con-
necting the container to the radiator neck, and a
pressure cap (Fig. 9) and (Fig. 10).
OPERATION
The system works in conjunction with the cooling
system pressure cap to utilize thermal expansion and
contraction of the coolant to keep the coolant free of
trapped air. The system provides space for expansion
and contraction. Also, the system provides a conve-
nient and safe method for checking and adjusting the
coolant level at atmospheric pressure without remov-
ing the pressure cap. It also provides some reserve
coolant to compensate for minor leaks and evapora-
tion or boiling losses.
Fig. 7 Spring Clamp Size Location
1 - SPRING CLAMP SIZE LOCATION
Fig. 8 Hose Clamp Tool
1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP
PT
ENGINE - 1.6L SOHC
7 - 19
COOLANT (Continued)
REMOVAL
(1) Siphon coolant from coolant recovery container.
(2) Remove vent hose clip from stud on dash panel
(Fig. 9).
(3) Disconnect overflow hose at radiator neck (Fig.
10).
(4) Remove container attaching fasteners (Fig. 9).
(5) Remove coolant recovery container.
INSTALLATION
(1) Install coolant recovery container and tighten
fasteners to 4 N·m (35 in. lbs.) (Fig. 9).
(2) To ensure proper vent hose routing, install vent
hose clip on stud at dash panel (Fig. 9).
(3) Connect overflow hose at radiator neck (Fig.
10).
(4) Fill coolant recovery container to proper level.
ENGINE BLOCK HEATER
DESCRIPTION
The heater is mounted in a core hole (in place of a
core hole plug) in the engine block near the starter
mounting location. The heating element immersed in
coolant (Fig. 11). The engine block heater is available
as an optional accessory. The heater is operated by
ordinary house current (110 Volt A.C.) through a
power cord and connector behind the radiator grille.
CAUTION: The power cord must be secured in its
retainer clips, and not positioned so it could con-
tact linkages or exhaust manifolds and become
damaged.
OPERATION
The block heater element is submerged in the cool-
ing system’s coolant. When electrical power (110 volt
A.C.) is applied to the element, it creates heat. This
heat is transferred to the engine coolant. This pro-
vides easier engine starting and faster warm-up
when vehicle is operated in areas having extremely
low temperatures.
DIAGNOSIS AND TESTING - ENGINE BLOCK
HEATER TESTING
If unit does not operate, trouble can be in either
the power cord or the heater element. Test power
cord for continuity with a 110-volt voltmeter or 110-
volt test light; test heater element continuity with an
ohmmeter or 12-volt test light.
REMOVAL
(1) Drain the cooling system (Refer to 7 - COOL-
ING/ENGINE - STANDARD PROCEDURE).
(2) Raise vehicle on hoist.
Fig. 9 Coolant Recovery Container
1 - NUT
2 - COOLANT RECOVERY CONTAINER
3 - SCREW
4 - VENT HOSE
5 - OVERFLOW HOSE
6 - CLIP
Fig. 10 Overflow Hose Routing
1 - RADIATOR NECK
2 - OVERFLOW HOSE
7 - 20
ENGINE - 1.6L SOHC
PT
COOLANT RECOVERY CONTAINER (Continued)
(3) Detach power cord plug from heater.
(4) Loosen screw in center of heater. Remove
heater assembly (Fig. 11).
INSTALLATION
(1) Thoroughly clean core hole and heater seat.
(2) Insert heater assembly with element loop posi-
tioned upward (Fig. 11).
(3) With
heater
seated,
tighten
center
screw
securely to assure a positive seal.
(4) Connect power cord to block heater.
(5) Lower vehicle.
(6) Fill the cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
ENGINE COOLANT TEMP
SENSOR
DESCRIPTION
The engine coolant temperature (ECT) sensor
threads into the rear of the cylinder head, below the
thermostat housing (Fig. 12). New sensors have seal-
ant applied to the threads. The ECT Sensor is a Neg-
ative Thermal Coefficient (NTC) sensor.
OPERATION
The ECT sensor provides an input to the PCM. As
temperature
increases,
resistance
of
the
sensor
decreases. As coolant temperature varies, the ECT
sensor resistance changes resulting in a different
voltage value at the PCM ECT sensor signal circuit.
The ECT sensor provides input for various PCM
operations. The PCM uses the input to control air-
fuel mixture, timing, and radiator fan on/off times.
The ECT sensor input is also used for temperature
gauge operation.
REMOVAL
(1) Disconnect negative battery cable.
(2) Disconnect positive battery cable.
(3) Remove battery.
(4) Partially drain cooling system.
(5) Disconnect coolant temperature sensor electri-
cal connector.
(6) Remove coolant temperature sensor (Fig. 12).
INSTALLATION
(1) Install coolant temperature sensor (Fig. 12).
Tighten sensor to 17 N·m (150 in. lbs.).
(2) Reconnect coolant temperature sensor connec-
tor.
(3) Install battery.
(4) Connect positive battery cable.
(5) Connect negative battery cable.
(6) Fill cooling system (Refer to 7 - COOLING/EN-
GINE - STANDARD PROCEDURE).
Fig. 11 Engine Block Heater
1 - BLOCK HEATER
2 - SCREW
Fig. 12 Engine Coolant Temperature Sensor
1 - ENGINE COOLANT TEMPERATURE SENSOR
PT
ENGINE - 1.6L SOHC
7 - 21
ENGINE BLOCK HEATER (Continued)
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