Chrysler PT Cruiser. Manual — part 455
ENGINE COOLANT
THERMOSTAT AND HOUSING
REMOVAL
(1) Disconnect negative battery cable.
(2) Disconnect positive battery cable.
(3) Remove battery.
(4) Partially drain cooling system.
(5) Remove fasteners securing heater return tube
to engine block and thermostat housing. Reposition
heater tube.
(6) Disconnect upper radiator hose and heater hose
from thermostat housing.
(7) Remove thermostat housing fasteners (Fig. 13).
INSTALLATION
(1) Clean all sealing surfaces.
(2) Place thermostat and seal into thermostat
housing. Align air bleed with notch in thermostat
housing (Fig. 14).
(3) Install
thermostat
housing
and
fasteners.
Torque fasteners to 7 N·m (65 in. lbs.) (Fig. 13).
(4) Connect upper radiator hose and heater hose to
thermostat housing.
(5) Install fasteners securing heater return tube to
engine block and thermostat housing.
(6) Install battery.
(7) Connect positive battery cable.
(8) Connect negative battery cable.
(9) Fill cooling system (Refer to 7 - COOLING/EN-
GINE - STANDARD PROCEDURE).
RADIATOR PRESSURE CAP
DESCRIPTION
The cooling system is equipped with a pressure cap
that releases built up pressure, maintaining a range
of 97-124 kPa (14-18 psi).
There is also a vent valve in the center of the cap.
This valve also opens when coolant is cooling and
contracting, allowing coolant to return to radiator
from coolant recovery container by vacuum through
connecting hose. If valve is stuck shut, the radia-
tor hoses will be collapsed on cool down. Clean
the vent valve (Fig. 15) to ensure proper sealing
when boiling point is reached.
OPERATION
The pressure cap allows the cooling system to oper-
ate at higher than atmospheric pressure. The higher
pressure raises the coolant boiling point; this allows
increased radiator cooling capacity.
The gasket in the cap seals the filler neck, so that
vacuum can be maintained, allowing coolant to be
drawn back into the radiator from the reserve con-
tainer.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING SYSTEM
PRESSURE CAP TESTING
Dip the pressure cap in water. Clean any deposits
off the vent valve or its seat and apply cap to end of
Fig. 13 Engine Coolant Thermostat Housing
1 - ENGINE COOLANT THERMOSTAT HOUSING
Fig. 14 Thermostat Orientation
1 - ALIGN AIR BLEED WITH NOTCH IN THERMOSTAT HOUSING
2 - THERMOSTAT SEAL
3 - THERMOSTAT HOUSING
7 - 22
ENGINE - 1.6L SOHC
PT
the Pressure Cap Test Adaptor that is included with
the
Cooling
System
Tester
7700.
Working
the
plunger, bring the pressure to 104 kPa (15 psi) on the
gauge. If the pressure cap fails to hold pressure of at
least 97 kPa (14 psi), replace the pressure cap.
CAUTION: The Cooling System Tester Tool is very
sensitive to small air leaks that will not cause cool-
ing system problems. A pressure cap that does not
have a history of coolant loss should not be
replaced just because it leaks slowly when tested
with this tool. Add water to the tool. Turn tool
upside down and recheck pressure cap to confirm
that cap is bad.
If the pressure cap tests properly while positioned
on Cooling System Tester (Fig. 16), but will not hold
pressure or vacuum when positioned on the filler
neck. Inspect the filler neck and cap top gasket for
irregularities that may prevent the cap from sealing
properly.
DIAGNOSIS AND TESTING - COOLING SYSTEM
PRESSURE RELIEF TESTING
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT
15
MINUTES
BEFORE
REMOVING
CAP.
PLACE A SHOP TOWEL OVER THE CAP, AND WITH-
OUT
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 CON-
TAINER AND PRESSURE DROPS, PUSH DOWN ON
THE CAP AND REMOVE IT COMPLETELY. SQUEEZ-
ING THE RADIATOR INLET HOSE WITH A SHOP
TOWEL (TO CHECK PRESSURE) BEFORE AND
AFTER TURNING TO THE FIRST STOP IS RECOM-
MENDED.
WARNING: THE WARNING WORDS “DO NOT OPEN
HOT” ON THE PRESSURE CAP IS A SAFETY PRE-
CAUTION. WHEN HOT, THE COOLING SYSTEM
BUILDS UP PRESSURE. TO PREVENT SCALDING
OR OTHER INJURY, THE PRESSURE CAP SHOULD
NOT BE REMOVED WHILE THE SYSTEM IS HOT
AND/OR UNDER PRESSURE.
The pressure cap upper gasket to filler neck seal
can be checked by removing the overflow hose at the
radiator filler neck overflow nipple (Fig. 15). Attach
the radiator pressure tester to the filler neck over-
flow nipple, and pump air into the system. The
pressure cap upper gasket should relieve pressure at
69-124 kPa (10-18 psi), and hold pressure at 55 kPa
(8 psi) minimum.
There is no need to remove the pressure cap at any
time except for the following purposes:
• Check and adjust coolant freeze point
• Refill system with new coolant
• Conducting service procedures
• Checking for leaks
CLEANING
Use only a mild soap to clean the pressure cap.
INSPECTION
Hold the cap in your hand, top side up (Fig. 15).
The vent valve at the bottom of the cap should open.
If the rubber gasket has swollen, preventing the
valve from opening, replace the cap.
Hold the cleaned cap in your hand, upside down.
If any light can be seen between vent valve and the
Fig. 15 Cooling System Pressure Cap
1 - OVERFLOW NIPPLE
2 - MAIN SPRING
3 - GASKET RETAINER
4 - STAINLESS-STEEL SWIVEL TOP
5 - RUBBER SEALS
6 - VENT VALVE
7 - RADIATOR
8 - FILLER NECK
Fig. 16 Pressure Testing Radiator Cap
1 - PRESSURE CAP
2 - PRESSURE TESTER
PT
ENGINE - 1.6L SOHC
7 - 23
RADIATOR PRESSURE CAP (Continued)
rubber gasket, replace the cap. Do not use a
replacement cap that has a spring to hold the
vent shut.
A replacement cap must be of the type designed for
coolant reserve systems. This design ensures coolant
return to the radiator.
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. 17) 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).
RADIATOR FAN
DESCRIPTION
The radiator cooling fan is a dual-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. 18). The radia-
tor fan is serviced as an assembly.
OPERATION
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. 19). Refer to the
label beneath the PDC cover for location of fan
relays.
Fig. 17 Draincock
1 - RADIATOR TANK
2 - DRAINCOCK
Fig. 18 Radiator Fan
1 - RADIATOR FAN SHROUD
2 - SCREWS
3 - SCREWS
7 - 24
ENGINE - 1.6L SOHC
PT
RADIATOR PRESSURE CAP (Continued)
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)
DIAGNOSIS AND TESTING - RADIATOR FAN
(Refer to Appropriate Diagnostic Information)
REMOVAL
NOTE: The fan motor, fan, and the shroud are ser-
viced as an assembly.
WARNING:
DO
NOT
REMOVE
THE
CYLINDER
BLOCK PLUG OR THE RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
(1) Disconnect negative cable from battery.
(2) Partially drain cooling system below upper
radiator hose level (Refer to 7 - COOLING/ENGINE -
STANDARD PROCEDURE).
(3) Remove grille (Refer to 23 - BODY/EXTERIOR/
GRILLE - REMOVAL).
(4) Remove upper radiator closure panel (Refer to
23
-
BODY/EXTERIOR/RADIATOR
CLOSURE
PANEL - REMOVAL) (Fig. 20).
(5) Disconnect upper radiator hose and overflow
hose from radiator filler neck (Fig. 21).
(6) Remove radiator filler neck (Fig. 21).
(7) Raise vehicle on hoist.
(8) Disconnect radiator fan electrical connector.
(9) Remove the two lower and left side radiator fan
screws (Fig. 18).
Fig. 19 Power Distribution Center (PDC)
1 - PCM
2 - PDC
Fig. 20 Upper Radiator Closure Panel and Center
Brace
1 - UPPER RADIATOR CLOSURE PANEL
2 - CENTER BRACE
PT
ENGINE - 1.6L SOHC
7 - 25
RADIATOR FAN (Continued)
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