Chrysler PT Cruiser. Manual — part 464
(9) Remove radiator assembly (Fig. 36) by lifting it
up from the engine compartment. Care should be
taken not to damage the cooling fins and tubes
during removal.
(10) Non-Turbo Vehicles: Remove the lower air
seal from radiator (Fig. 34).
CLEANING
Clean radiator fins are necessary for good heat
transfer. The radiator and air conditioning fins
should be cleaned when an accumulation of debris
has occurred. With the engine cold, apply cold water
and compressed air to the back (engine side) of the
radiator to flush the radiator and/or A/C condenser of
debris.
Fig. 33 Radiator Hose Connections
1 - RADIATOR
2 - RADIATOR UPPER HOSE
3 - RADIATOR LOWER HOSE
4 - CLAMP
5 - TRANSMISSION OIL COOLER HOSES
6 - CLAMP
Fig. 34 Air Seals
1 - A/C CONDENSER
2 - SIDE AIR SEALS
3 - LOWER AIR SEAL
Fig. 35 Cooling Module Fasteners - 2.4L Turbo
1 - RADIATOR FAN FASTENERS
2 - CONDENSER FASTENERS
3 - TRANSMISSION OIL COOLER FASTENERS
4 - RADIATOR FAN/CONDENSER FASTENER
5 - CHARGE AIR COOLER FASTENERS
Fig. 36 Cooling Module Assembly
1 - UPPER RADIATOR CLOSURE PANEL
2 - COOLING MODULE
3 - RADIATOR FAN CONNECTOR
4 - LOWER RADIATOR CROSSMEMBER
7 - 58
ENGINE - 2.0/2.4L DOHC
PT
RADIATOR (Continued)
INSPECTION
Inspect the radiator tanks for cracks, broken or
missing fittings also inspect the joint where the
tanks seam up to the radiator core for signs of leak-
age and/or deteriorating seals.
Inspect radiator core for corroded, bent or missing
cooling fins. Inspect the core for bent or damaged
cooling tubes.
INSTALLATION
(1) Non-Turbo Vehicles: Install the lower air seal
to radiator (Fig. 34).
NOTE: Turbocharger Equipped Vehicles: When low-
ering
radiator,
make
sure
lower
radiator
pins
engage properly through charge air cooler locating
tabs (Fig. 37).
(2) Position radiator into mounting position.
(3) Position A/C condenser against radiator. Hand
start fasteners.
(4) Turbocharger Equipped Vehicles: Install
fasteners attaching charge air cooler to radiator.
Torque fasteners to 8 N·m (70 in. lbs.) (Fig. 35).
(5) Install radiator fan/shroud assembly. Hand
start fasteners.
(6) Torque all condenser fasteners to 8 N·m (70 in.
lbs.).
(7) Torque all radiator fan fasteners to 6 N·m (55
in. lbs.).
(8) Non-Turbo Vehicles with Automatic Trans-
mission: Install fasteners attaching transmission oil
cooler to radiator. Torque fasteners to 8 N·m (70 in.
lbs.).
(9) Raise vehicle on hoist.
(10) Non-Turbo Vehicles: Connect the lower air
seal to the side air seals (Fig. 34).
(11) Connect lower radiator hose (Fig. 33). Align
the hose and position the clamp so it will not inter-
fere with engine components.
(12) Connect the radiator fan electrical connector.
(13) Turbocharger Equipped Vehicles: Connect
the power steering hoses.
(14) Close radiator draincock.
(15) Lower vehicle.
(16) Turbocharger equipped vehicles: Inspect
radiator inlet neck o-ring. Replace if necessary.
Install radiator inlet neck. Torque fasteners to 6 N·m
(55 in. lbs.).
(17) Connect upper radiator hose (Fig. 33). Align
the hose and position the clamp to prevent interfer-
ence with the engine or hood.
(18) Install upper radiator closure panel and cen-
ter brace (Refer to 23 - BODY/EXTERIOR/RADIA-
TOR CLOSURE PANEL - INSTALLATION).
(19) Install grille (Refer to 23 - BODY/EXTERIOR/
GRILLE - INSTALLATION).
(20) Install battery tray and battery.
(21) Connect positive battery cable. Connect nega-
tive battery cable.
(22) Install air cleaner housing assembly.
(23) Fill cooling system with coolant (Refer to 7 -
COOLING/ENGINE - STANDARD PROCEDURE).
(24) Operate engine until it reaches normal oper-
ating temperature. Check cooling system for correct
fluid level.
(25) Turbocharger Equipped Vehicles: Check
power steering fluid level. Fill as needed.
Fig. 37 Charge Air Cooler Locating Tab
1 - LOCATING TAB
2 - LOWER RADIATOR SUPPORT CROSSMEMBER
3 - RADIATOR MOUNT BUSHING
4 - CHARGE AIR COOLER
PT
ENGINE - 2.0/2.4L DOHC
7 - 59
RADIATOR (Continued)
RADIATOR DRAINCOCK
REMOVAL
CAUTION: Use of pliers on draincock is not recom-
mended. Damage may occur to radiator or drain-
cock.
NOTE: It is not necessary to remove draincock dur-
ing a routine coolant drain.
(1) Drain the cooling system (Refer to 7 - COOL-
ING/ENGINE - STANDARD PROCEDURE).
(2) Open the draincock by turning it counterclock-
wise until it stops.
(3) Turn the draincock back (clockwise) 1/8 turn.
(4) Pull the draincock (Fig. 38) from the radiator
tank.
INSTALLATION
(1) Align draincock stem to radiator tank opening.
(2) Push draincock into the radiator tank opening.
(3) Tighten the draincock by turning clockwise
until it stops.
(4) Fill the cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
THERMOSTAT HOUSING
REMOVAL
(1) Disconnect negative battery cable.
(2) Drain cooling system below thermostat housing
level (Refer to 7 - COOLING/ENGINE - STANDARD
PROCEDURE).
(3) Remove thermostat (Refer to 7 - COOLING/
ENGINE/ENGINE
COOLANT
THERMOSTAT
-
REMOVAL).
(4) Disconnect engine coolant temperature sensor.
(5) Disconnect heater supply hose.
(6) Turbocharger equipped vehicles:
• Recover the refrigerant from the refrigerant sys-
tem(Refer to 24 - HEATING & AIR CONDITIONING
- STANDARD PROCEDURE).
• Disconnect A/C suction line from A/C compressor
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/SUCTION LINE - REMOVAL).
(7) Remove housing attaching bolts (Fig. 39).
(8) Remove housing and gasket (Fig. 39).
Fig. 38 Draincock
1 - RADIATOR TANK
2 - DRAINCOCK
Fig. 39 Thermostat Housing
1 - THERMOSTAT HOUSING
2 - COOLANT TEMPERATURE SENSOR
3 - HOSE-HEATER SUPPLY
4 - BOLTS
7 - 60
ENGINE - 2.0/2.4L DOHC
PT
INSTALLATION
(1) Clean all gasket sealing surfaces.
(2) Install gasket and housing (Fig. 39). Tighten
bolts to 28 N·m (20 ft. lbs.).
(3) Turbocharger equipped vehicles:
• Connect A/C suction line to A/C compressor
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/SUCTION LINE - INSTALLATION).
• Evacuate the refrigerant system(Refer to 24 -
HEATING & AIR CONDITIONING - STANDARD
PROCEDURE).
• Charge the refrigerant system(Refer to 24 -
HEATING & AIR CONDITIONING - STANDARD
PROCEDURE).
(4) Connect heater supply hose.
(5) Connect engine coolant temperature sensor.
(6) Install thermostat (Refer to 7 - COOLING/EN-
GINE/ENGINE
COOLANT
THERMOSTAT
-
INSTALLATION).
(7) Fill cooling system (Refer to 7 - COOLING/EN-
GINE - STANDARD PROCEDURE).
(8) Connect negative battery cable.
WATER PUMP
DIAGNOSIS AND TESTING
WATER PUMP
A quick flow test to determine if the water pump is
working effectively is to check heater system for
proper operation. A defective pump will not provide
an adequate flow of heated coolant through the sys-
tem.
WARNING: DO NOT REMOVE THE COOLING SYS-
TEM PRESSURE CAP WITH THE SYSTEM HOT AND
UNDER PRESSURE BECAUSE SERIOUS BURNS
FROM COOLANT CAN OCCUR.
Another flow test to help determine water pump
operation is as follows:
(1) Remove cooling system pressure cap.
(2) Remove a small amount of coolant from the
system.
(3) Start the engine and warm up until thermostat
opens.
(4) With the thermostat open and coolant level low,
visually inspect for coolant flow. If flow is present,
the water pump is pumping coolant through the sys-
tem.
REMOVAL
(1) Drain cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(3) Remove camshaft sprockets and rear timing
belt cover (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT AND SPROCKETS - REMOVAL).
(4) Remove
screws
attaching
water
pump
to
engine. Remove pump (Fig. 40).
INSPECTION
Replace water pump body assembly if it has any of
these defects:
(1) Cracks or damage on the body.
(2) Coolant leaks from the shaft seal, evident by
wet coolant traces on the pump body.
(3) Loose or rough turning bearing.
(4) Impeller rubs either the pump body or the
engine block.
(5) Impeller loose or damaged.
(6) Sprocket or sprocket flange loose or damaged.
INSTALLATION
(1) Apply Mopar
t Dielectric Grease to new O-ring
before installation (Fig. 41).
(2) Install O-ring gasket in water pump body
groove (Fig. 41).
Fig. 40 Water Pump
1 - CYLINDER BLOCK
2 - WATER PUMP
PT
ENGINE - 2.0/2.4L DOHC
7 - 61
THERMOSTAT HOUSING (Continued)
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