Chrysler PT Cruiser. Manual — part 753
(14) Remove the pencil strut from the right front
corner of the crossmember and body of the vehicle.
(Fig. 9). Remove the washer behind the strut from
the torque strut bolt.
(15) Remove the screws fastening the front fascia
to the reinforcement as necessary in order to access
the drive-belt splash shield forward fastener screw
(Fig. 10).
(16) Remove the drive-belt splash shield fasteners
(Fig. 10). Remove the shield.
(17) Remove the bolt mounting the engine torque
strut to the right forward corner of the front suspen-
sion crossmember (Fig. 9).
NOTE: Before removing the front suspension cross-
member from the vehicle, the location of the cross-
member must be scribed on the body of the vehicle
(Fig. 9). Do this so the crossmember can be relo-
cated, upon reinstallation, against the body of vehi-
cle in the same location as before removal. If the
front suspension crossmember is not reinstalled in
exactly the same location as before removal, the
preset front wheel alignment settings (caster and
camber) will be lost.
(18) Using an awl, scribe a line marking the loca-
tion of where the front suspension crossmember is
mounted against the body of the vehicle (Fig. 11).
(19) Position a transmission jack under the center
of the front suspension crossmember and raise it to
support the bottom of the crossmember.
(20) Loosen all six bolts attaching the front sus-
pension crossmember to the frame rails of vehicle. Do
not completely remove the two mounting bolts going
through the lower control arm rear isolator bushings.
They are designed to disengage from the body
threads yet stay within the lower control arm rear
isolator bushing. Back the two bolts out just enough
to disengage the threaded tapping plates in the body
of the vehicle. Completely remove the other four
bolts.
(21) Lower
the
front
suspension
crossmember
using the transmission jack enough to allow the
power steering gear to be removed from the rear of
the crossmember (Fig. 12). When lowering front sus-
pension crossmember, do not let crossmember hang
from lower control arms. The weight should be sup-
ported by the transmission jack.
Fig. 9 Strut Mounting
1 - NUT
2 - PENCIL STRUT
3 - NUT
4 - FLAT WASHER
5 - LOWER TORQUE STRUT
Fig. 10 Fascia And Splash Shield Fasteners
1 - FASCIA FASTENERS
2 - FASCIA FASTENERS
3 - SPLASH SHIELD FASTENERS
Fig. 11 Marking Crossmember Location
1 - SCRIBED LINE
2 - AWL
3 - CROSSMEMBER
19 - 30
GEAR
PT
GEAR (Continued)
(22) Remove the roll pin securing the steering col-
umn lower coupling to the power steering gear pinion
shaft using a roll pin punch (Fig. 13). Push the steer-
ing column lower coupling up and off of the power
steering gear pinion shaft.
(23) Release the pinion shaft dash cover seal from
the tabs cast into the power steering gear housing
and remove the seal from the power steering gear
(Fig. 14).
(24) Loosen and remove the four bolts attaching
the power steering gear to the front suspension cross-
member (Fig. 1). Remove the power steering gear
from the front suspension crossmember.
REMOVAL - RHD
Right-Hand-Drive power steering gear is typical of
Left-Hand-Drive. (Refer to 19 - STEERING/GEAR -
REMOVAL - LHD)
INSTALLATION
INSTALLATION
(1) Install the steering gear on the front suspen-
sion crossmember (Fig. 1). Install the four power
steering gear mounting bolts. Tighten the mounting
bolts to a torque of 61 N·m (45 ft. lbs.).
(2) Install the pinion shaft dash cover seal over
the power steering pinion shaft and onto the power
steering gear housing. Align the holes on each side of
the seal with the tabs cast into the power steering
gear housing (Fig. 14).
(3) With
the
steering
column
lower
coupling
pushed partway up through its hole in the dash
panel, match the flat on the inside of the steering
column lower coupling to the flat on the power steer-
ing gear pinion shaft and slide the coupling onto the
top of the pinion shaft. Align the roll pin hole in the
coupling with the groove in the pinion shaft and
install the roll pin through the coupling until it is
centered (Fig. 13).
(4) Center the power steering gear rack in its travel.
(5) Using the transmission jack, raise the front
suspension crossmember and power steering gear
until the crossmember contacts its mounting spot
against the body and frame rails of the vehicle. As
the crossmember is raised, carefully guide the steer-
ing column lower coupling up through its hole in the
dash panel.
Fig. 12 Crossmember Lowered
1 - STEERING COLUMN LOWER COUPLING
2 - POWER STEERING GEAR
3 - FRONT SUSPENSION CROSSMEMBER
4 - TRANSMISSION JACK
Fig. 13 Coupling Roll Pin
1 - STEERING COLUMN LOWER COUPLING
2 - POWER STEERING GEAR PINION SHAFT
3 - ROLL PIN
4 - ROLL PIN PUNCH
Fig. 14 Pinion Shaft Dash Cover Seal
1 - SEAL
2 - PINION SHAFT
3 - TAB
4 - POWER STEERING GEAR
PT
GEAR
19 - 31
GEAR (Continued)
(6) Start the two crossmember mounting bolts
through the lower control arm rear isolator bushings
into the tapping plates mounted in the body. Next,
install the two front and the two rear mounting bolts
attaching front suspension crossmember to frame
rails of vehicle. Lightly tighten all six mounting bolts
to approximately 2 N·m (20 in. lbs.) to hold the front
suspension crossmember in position at this time.
NOTE:
When
reinstalling
the
front
suspension
crossmember back in the vehicle, it is very impor-
tant that the crossmember be attached to the body
in exactly the same spot as when it was removed.
Otherwise, the vehicle’s wheel alignment settings
(caster and camber) will be lost.
(7) Using a soft face hammer, tap the front suspen-
sion crossmember back-and-forth or side-to-side until
it is aligned with the previously scribed positioning
marks on the body of the vehicle (Fig. 11). Once the
front suspension crossmember is correctly positioned,
tighten the two crossmember mounting bolts through
the lower control arm rear isolator bushings to a
torque of 250 N·m (185 ft. lbs.), then tighten the four
remaining crossmember mounting bolts to a torque of
153 N·m (113 ft. lbs.).
(8) Fasten the engine torque strut to the right for-
ward corner of the front suspension crossmember
using its mounting bolt (Fig. 9). Follow the procedure
described in the ENGINE section to properly align
and tighten the torque strut and it’s mounting bolts.
(Refer
to
9
-
ENGINE/ENGINE
MOUNTING/
TORQUE STRUT - ADJUSTMENTS)
(9) Install the washer on the end of the stud
extending from the torque strut bolt (Fig. 9).
(10) Install the pencil strut to the right front cor-
ner of the crossmember and body of the vehicle (Fig.
9). Tighten the pencil strut nuts to a torque of 52
N·m (38 ft. lbs.).
(11) Install the drive-belt splash shield and fasten-
ers (Fig. 10).
(12) Install the screws fastening the front fascia to
the reinforcement (Fig. 10).
(13) Using a lint free towel, wipe clean the open
power steering hose ends and the power steering
gear ports. Replace the pressure hose used O-ring
with new. Lubricate the O-ring with power steering
fluid.
(14) On
vehicles
equipped
with
crossmember
mounted power steering fluid coolers:
(a) Place the cooler in mounting position and
snap the cooler tube going to the gear into the
right routing clip on the front of the gear. Close the
routing clip.
(b) Install the two screws securing the cooler to
the front suspension crossmember (Fig. 7). Tighten
the screws to a torque of 10 N·m (90 in. lbs.).
(15) Slide the cooler or return hose onto the steel
gear outlet port fitting (Fig. 7) (Fig. 8). Secure the
clamp on the hose past the bead on the steel fitting.
CAUTION: On vehicles equipped with crossmember
mounted power steering fluid coolers, forward of
the steering gear, the power steering fluid pressure
hose routes between the front suspension cross-
member and the driveshaft. When tightening the
pressure hose tube nut to the steering gear, the
pressure hose must be positioned (clocked) such
that its final routing (after tightened to 31 N·m (23 ft.
lbs.)) offers 4–10 mm clearance to the front suspen-
sion crossmember (measured at the pressure hose
steel-to-rubber coupling). There should be a clock-
ing donut on the hose to preset this distance.
(16) Attach the power steering fluid pressure hose
to its port on the power steering gear (Fig. 7) (Fig. 8).
(17) On turbocharged engined vehicles, install
routing clip up from gear outlet tube onto fluid pres-
sure hose tube (Fig. 8).
(18) While making sure the pressure hose is not in
contact with any vehicle components (see preceding
caution), tighten the pressure hose tube nut at the
gear to 31 N·m (23 ft. lbs.) torque.
(19) On vehicles equipped with a power steering
fluid pressure switch, reconnect the wiring harness
connector at the power steering fluid pressure switch
(Fig. 6). Be sure the locking tab on the wiring har-
ness connector is securely latched.
(20) Perform the following to each outer tie rod:
(a) Place the tie rod heat shield on the knuckle’s
steering arm, aligning the hole in the shield with
the hole in the knuckle and the tangs on the out-
side of the shield with the outside configuration of
the steering arm. The shield should now be facing
outboard, away from the power steering gear and
tie rod (Fig. 4).
(b) Attach the outer tie rod end to its steering
knuckle.
(c) Start the attaching nut onto the stud of the
outer tie rod.
(d) While holding the stud of the tie rod station-
ary with a wrench, tighten the attaching nut (Fig.
4).
(e) Using a crowfoot wrench attached to a torque
wrench, tighten the attaching nut to 54 N·m (40 ft.
lbs.).
(21) Install the tire and wheel assemblies back on
vehicle. Tighten the wheel mounting nuts to 135 N·m
(100 ft. lbs.) torque.
(22) Lower the vehicle to ground level.
(23) Install the dash-to-lower coupling seal in
place over the lower coupling’s plastic collar.
19 - 32
GEAR
PT
GEAR (Continued)
NOTE: Verify that grease is present on the lip of the
dash-to-coupling seal where it contacts the cou-
pling’s plastic collar.
(24) Inside the passenger compartment, reconnect
the steering column lower coupling to the steering
column upper coupling (Fig. 3). Install the coupling
pinch bolt and tighten the pinch bolt nut to a torque
of 28 N·m (250 in. lbs.). Install the pinch bolt
retainer pin.
(25) Remove the steering wheel holder.
(26) While looking under the instrument panel at
the lower coupling, rotate the steering wheel back-
and-forth to verify that the lower coupling does not
squeak against the dash-to-coupling seal.
(27) Install the knee blocker.
(28) Install
the
silencer
pad
below
the
knee
blocker panel below the steering column.
(29) Perform the POWER STEERING PUMP INI-
TIAL OPERATION service procedure to properly fill
and bleed the power steering system. (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE)
(30) Check for fluid leaks.
(31) Adjust the front toe setting on the vehicle.
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE)
INSTALLATION - RHD
Right-Hand-Drive power steering gear is typical of
Left-Hand-Drive. (Refer to 19 - STEERING/GEAR -
INSTALLATION - LHD)
POWER STEERING PRESSURE
SWITCH
DESCRIPTION
A power steering pressure switch is used on some
versions of this vehicle to improve the vehicle’s idle
quality. The pressure switch improves vehicle idle
quality by causing a readjustment of the engine idle
speed as necessary when increased fluid pressure is
sensed in the power steering system.
The pressure switch functions by signaling the
powertrain control module that an increase in pres-
sure of the power steering system is putting addi-
tional load on the engine. This type of condition
exists when the front tires of the vehicle are turned
while the vehicle is stationary and the engine is at
idle speed. When the powertrain control module
receives the signal from the power steering pressure
switch, it directs the engine to increase its idle speed.
This increase in engine idle speed compensates for
the additional load, thus maintaining the required
engine idle speed and idle quality.
The power steering pressure switch is mounted
directly to the power steering gear (Fig. 15).
OPERATION
The switch provides an input to the PCM during
periods of high pump load and low engine RPM; such
as during parking maneuvers.
When power steering pump pressure exceeds 2758
kPa (400 psi), the switch is open. The PCM increases
idle air flow through the IAC motor to prevent
engine stalling. The PCM sends 12 volts through a
resister to the sensor circuit to ground. When pump
pressure is low, the switch is closed.
REMOVAL
NOTE: Before proceeding, (Refer to 19 - STEERING
- WARNING).
(1) Disconnect negative battery cable from the neg-
ative post of the battery. Be sure cable is isolated
from negative post on battery.
(2) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(3) Locate the power steering fluid pressure switch
on the back side of the power steering gear (Fig. 15).
(4) Remove the vehicle wiring harness connector
from the power steering fluid pressure switch.
NOTE: When removing and installing the power
steering pressure switch, use a 7/8 inch deep well
socket. The deep well socket will prevent damage
to the plastic electrical connector area of the power
steering fluid pressure switch.
Fig. 15 Switch Location
1 - WIRING HARNESS CONNECTOR
2 - POWER STEERING GEAR
3 - POWER STEERING FLUID PRESSURE SWITCH
4 - REAR OF FRONT SUSPENSION CROSSMEMBER
PT
GEAR
19 - 33
GEAR (Continued)
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