Chrysler PT Cruiser. Manual — part 460
DIAGNOSIS AND TESTING - COOLING SYSTEM
LEAK TESTING
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT 15 MINUTES BEFORE REMOVING PRESSURE
CAP. PLACE A SHOP TOWEL OVER THE CAP, AND
WITHOUT PUSHING DOWN, ROTATE IT COUNTER-
CLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS
TO ESCAPE THROUGH THE OVERFLOW TUBE.
WHEN THE SYSTEM STOPS PUSHING COOLANT
AND STEAM INTO THE COOLANT RECOVERY BOT-
TLE AND PRESSURE DROPS, PUSH DOWN ON THE
CAP AND REMOVE IT COMPLETELY. SQUEEZING
THE RADIATOR INLET HOSE WITH A SHOP TOWEL
(TO CHECK PRESSURE) BEFORE AND AFTER
TURNING TO THE FIRST STOP IS RECOMMENDED.
The cooling system should be full. Add coolant if
necessary.
With engine not running, wipe the coolant filler
neck sealing seat clean.
Attach a cooling system pressure tester (Special
Tool 7700 or equivilent) to the coolant filler neck, as
shown in (Fig. 4) and apply 104 kPa (15 psi) pres-
sure. If the pressure drops more than 2 psi in 2 min-
utes inspect all points for external leaks. For Special
Tool identification, (Refer to 7 - COOLING - SPE-
CIAL TOOLS).
Move all hoses at the radiator and heater while
system is pressurized at 104 kPa (15 psi), since some
leaks occur while driving due to engine movement
while driving.
If there are no external leaks after the gauge dial
shows a drop in pressure, detach the tester. Start
engine and run the engine to normal operating tem-
perature in order to open the thermostat and allow
the coolant to expand. Reattach the tester. If the nee-
dle on the dial fluctuates, it indicates a combustion
leak and is usually a head gasket leak.
WARNING:
WITH
TOOL
IN
PLACE
PRESSURE
BUILDS UP FAST. ANY EXCESSIVE AMOUNT OF
PRESSURE BUILT UP BY CONTINUOUS ENGINE
OPERATION MUST BE RELEASED TO A SAFE
PRESSURE POINT. NEVER PERMIT PRESSURE TO
EXCEED 138 kPa (20 psi).
If the needle on the dial does not fluctuate, race
the engine a few times. If an abnormal amount of
coolant or steam is emitted from the tailpipe, it may
indicate a faulty head gasket, cracked engine block or
cylinder head.
There may be internal leaks which can be deter-
mined by removing the oil dipstick. If water globules
appear intermixed with the oil, it will indicate a
internal leak in the engine. If there is an internal
leak, the engine must be disassembled for repair.
DIAGNOSIS AND TESTING - COOLING SYSTEM
FLOW CHECK
To determine whether coolant is flowing through
the cooling system, use one of the following proce-
dures:
PREFERRED METHOD
WARNING: DO NOT REMOVE THE COOLING SYS-
TEM PRESSURE CAP OR ANY HOSE WITH THE
SYSTEM HOT AND UNDER PRESSURE BECAUSE
SERIOUS BURNS FROM COOLANT CAN OCCUR.
• Remove pressure cap when engine is cold.
Remove small amount of coolant. Idle engine until
thermostat opens. You should observe coolant flow
while looking down the filler neck. Once flow is
detected install the pressure cap. Replace removed
coolant into coolant recovery container.
ALTERNATIVE METHOD
• If engine is cold, idle engine until normal oper-
ating temperature is reached. Feel the upper radiator
hose. If it is hot, coolant is circulating.
COOLING SYSTEM AERATION
Low coolant level in the cooling system will cause
aeration, resulting in the following conditions:
• Corrosion in the system
• High reading shown on the temperature gauge
• Loss of coolant flow through the heater
• Exhaust gas leaks into the coolant can also
cause the above problems
Fig. 4 Pressure Testing Cooling System
1 - SPECIAL TOOL 7700
7 - 42
ENGINE - 2.0/2.4L DOHC
PT
ENGINE - 2.0/2.4L DOHC (Continued)
DIAGNOSIS AND TESTING - COOLING SYSTEM
DEAERATION
Air can only be removed from the system by gath-
ering under the pressure cap. On the next heat up it
will be pushed past the pressure cap into the coolant
recovery bottle by thermal expansion of the coolant.
It then escapes to the atmosphere in the coolant
recovery bottle and is replaced with coolant on cool
down.
To effectively deaerate the system, multiple ther-
mal cycles of the system may be required.
NOTE: Deaeration does not occur at engine idle—
higher engine speeds are required. Normal driving
will deaerate cooling system.
STANDARD PROCEDURE
STANDARD PROCEDURE - DRAINING COOLING
SYSTEM
WARNING: DO NOT OPEN THE RADIATOR DRAIN-
COCK WITH THE SYSTEM HOT AND UNDER PRES-
SURE. SERIOUS BURNS FROM COOLANT CAN
OCCUR.
NOTE: Drain, flush, and fill the cooling system at
the mileage or time intervals specified in the MAIN-
TENANCE SCHEDULE (Refer to LUBRICATION &
MAINTENANCE/MAINTENANCE
SCHEDULES
-
DESCRIPTION). If the solution is dirty, rusty, or con-
tains a considerable amount of sediment; clean and
flush with a reliable cooling system cleaner. Care
should be taken in disposing of the used engine
coolant from your vehicle. Check governmental reg-
ulations for disposal of used engine coolant.
(1) Position a clean collecting container under
draincock location.
(2) Without removing the pressure cap and with
system not under pressure, turn draincock counter-
clockwise to open (Fig. 5).
(3) The coolant reserve bottle should empty first,
then remove the pressure cap.
(4) If coolant reserve bottle does not empty first:
(a) Check condition of the pressure cap and cap
seals.
(b) Check for kinked/torn overflow hose from
filler neck to reserve bottle.
(5) Allow cooling system to drain completely.
STANDARD PROCEDURE - FILLING COOLING
SYSTEM
WARNING: MAKE SURE ENGINE COOLING SYSTEM
IS COOL BEFORE REMOVING PRESSURE CAP OR
ANY HOSE. THE COOLING SYSTEM IS PRESSUR-
IZED WHEN HOT. SEVERE PERSONAL INJURY MAY
RESULT FROM ESCAPING HOT COOLANT.
CAUTION: Do not use well water, or suspect water
supply in cooling system. A 50/50 mixture of the
recommended ethylene glycol and distilled water is
recommended. For recommended coolant usage,
(Refer to LUBRICATION & MAINTENANCE/FLUID
TYPES - DESCRIPTION).
NOTE:
For
cooling
system
capacity
(Refer
to
LUBRICATION & MAINTENANCE/SPECIFICATIONS -
FLUID CAPACITIES).
(1) Close radiator draincock. Hand tighten only.
(2) Open, but do not remove cooling system bleed
valve (Fig. 6).
(3) Attach a 6.35 mm (0.250 in.) inside diameter
clear hose that is 120.0 cm (48 in.) long to the bleed
valve. Route the hose away from the accessory drive
belts and radiator fan. Position the other end of the
hose into a collecting container. The hose will prevent
coolant from contacting the accessory drive belts, A/C
compressor, and other components.
(4) Remove
the
cooling
system
pressure
cap.
Install Special Tool 8195 Filling Aid Funnel (Fig. 7).
(5) Use the supplied clip to pinch overflow hose
(Fig. 7).
NOTE: Be careful not to spill coolant on drive belts
or the generator.
Fig. 5 Cooling System Draincock Location
PT
ENGINE - 2.0/2.4L DOHC
7 - 43
ENGINE - 2.0/2.4L DOHC (Continued)
NOTE: While filling the cooling system, pour cool-
ant into the larger section of the Filling Aid Funnel
8195.
(6) Slowly fill the cooling system until a steady
stream of coolant flows from the attached hose on the
bleed valve.
(7) Close the bleed valve and remove the hose.
(8) Remove clip from overflow hose and remove
funnel 8195.
(9) Fill coolant to the top of the pressure cap neck.
(10) Install cooling system pressure cap.
CAUTION: Coolant may leak out of the bottle over-
flow tube if filling too rapidly.
(11) Slowly fill coolant reserve/recovery bottle to at
least the FULL HOT mark with the recommended
coolant. It may be necessary to add additional cool-
ant to the reserve/recovery bottle after three or four
warm-up/cool down cycles to maintain coolant level
between the FULL HOT and ADD marks.This is due
to the removal of trapped air from the system.
CLEANING
CAUTION:
Internal
radiator
pressure
must
not
exceed 138 kPa (20 psi) as damage to radiator may
result.
Reverse flushing of cooling system is the forcing of
water through the cooling system. This is done using
air pressure in the opposite direction of normal cool-
ant flow. It is usually only necessary with very dirty
systems with evidence of partial plugging.
(1) Drain cooling system. Remove thermostat hous-
ing and thermostat. Install thermostat housing.
(2) Connect a suitable cooling system flusher and
follow instructions supplied with flusher.
INSPECTION
After
performing
a
cleaning/flush
procedure,
inspect all hoses, clamps and connections for deterio-
ration and leaks. Inspect radiator and heater core for
leaks.
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
Fig. 6 Cooling System Bleed Valve
Fig. 7 Filling the Cooling System
1 - SPECIAL TOOL 8195 FILLING AID FUNNEL
2 - PINCH OVERFLOW HOSE
7 - 44
ENGINE - 2.0/2.4L DOHC
PT
ENGINE - 2.0/2.4L DOHC (Continued)
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 - 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 pressure cap. Simply observe,
with the engine idling and warmed up to normal
operating temperature, that the level of the coolant
in the recovery/reserve bottle (Fig. 8) is between the
FULL HOT and ADD marks.
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
NOTE: The radiator cap should not be removed.
When additional coolant is needed, it should be
added to the coolant recovery container (Fig. 9) or
(Fig. 10). Use only the recommended 50/50 mixture of
ethylene glycol type antifreeze and distilled water
(Refer
to
7
-
COOLING/ENGINE/COOLANT
-
DESCRIPTION).
CAUTION: COOLANT MAY LEAK OUT OF THE BOT-
TLE OVERFLOW TUBE WHILE FILLING RAPIDLY.
STANDARD PROCEDURE - COOLANT LEVEL
SERVICING
NOTE: The cooling system is closed and designed
to maintain coolant level to the top of the radiator.
When servicing requires a coolant level check in
the radiator, the engine must be off and not under
pressure. Drain several ounces of coolant from the
radiator drain cock while observing the coolant recov-
ery container. Coolant level in the container should
drop slightly. Remove the pressure cap (Fig. 9) or
(Fig. 10). The radiator should be full to the top. If
not, and the coolant level in the recovery contianer is
at the ADD mark, there is a air leak in the coolant
recovery system. Check hose or hose connections to
the recovery container, outlet connector neck or the
pressure cap seal at outlet connector for leaks.
Fig. 8 Coolant Level
PT
ENGINE - 2.0/2.4L DOHC
7 - 45
COOLANT (Continued)
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