Chrysler PT Cruiser. Manual — part 456
(10) Lower vehicle and remove the remaining radi-
ator fan attaching screws (Fig. 18).
CAUTION: Care should be taken not to damage the
radiator cooling fins and tubes during fan removal.
(11) Remove radiator fan by lifting up from the
engine compartment.
INSTALLATION
(1) Install the radiator fan into position on the
radiator.
(2) Install the upper and right side radiator fan
retaining screws and tighten to 6 N·m (55 in. lbs.)
(Fig. 18).
(3) Raise vehicle and install the remaining fan
attaching screws. Tighten to 6 N·m (55 in. lbs.) (Fig.
18).
(4) Connect radiator fan electrical connector.
(5) Lower vehicle.
(6) Install radiator filler neck to radiator. Connect
upper radiator hose and overflow hose to radiator
filler neck (Fig. 21).
(7) Install upper radiator closure panel (Refer to
23
-
BODY/EXTERIOR/RADIATOR
CLOSURE
PANEL - INSTALLATION) (Fig. 20).
(8) Install grille (Refer to 23 - BODY/EXTERIOR/
GRILLE - INSTALLATION).
(9) Connect negative battery cable.
(10) Fill the cooling system (Refer to 7 - COOL-
ING/ENGINE - STANDARD PROCEDURE).
RADIATOR
REMOVAL
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.
NOTE: It is not necessary to discharge the air con-
ditioning system to remove the radiator.
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist.
(3) Drain the cooling system (Refer to 7 - COOL-
ING/ENGINE - STANDARD PROCEDURE).
(4) Disconnect radiator fan motor electrical connec-
tor (Fig. 22).
Fig. 21 Radiator Filler Neck
1 - FAN MOUNTING NUT
2 - RADIATOR FILLER NECK
3 - FAN
Fig. 22 Cooling Module
1 - UPPER RADIATOR CROSSMEMBER
2 - COOLING MODULE
3 - RADIATOR FAN CONNECTOR
4 - LOWER RADIATOR CROSSMEMBER
7 - 26
ENGINE - 1.6L SOHC
PT
RADIATOR FAN (Continued)
(5) Disconnect lower radiator hose.
(6) Remove two lower fasteners attaching radiator
fan shroud to radiator (Fig. 23).
(7) Dislodge lower radiator air seal from side radi-
ator air seals (Fig. 24).
(8) Lower vehicle.
(9) Remove grille (Refer to 23 - BODY/EXTERIOR/
GRILLE - REMOVAL).
(10) Remove upper radiator closure panel (Refer to
23
-
BODY/EXTERIOR/RADIATOR
CLOSURE
PANEL - REMOVAL).
(11) Disconnect upper radiator hose and overflow
hose from the radiator filler neck (Fig. 25).
(12) Remove remaining fasteners attaching radia-
tor fan shroud to radiator (Fig. 23).
(13) Remove radiator fan/shroud assembly.
(14) Remove remaining fasteners attaching AC
condenser to radiator. Reposition AC condenser.
(15) Remove radiator assembly by lifting it up
from the engine compartment. Care should be
taken not to damage the cooling fins and tubes
during removal.
(16) Remove the lower air seal from radiator (Fig.
24).
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. 23 Radiator Fan - Mounting
1 - RADIATOR FAN SHROUD
2 - SCREWS
3 - SCREWS
Fig. 24 Air Seals
1 - A/C CONDENSER
2 - SIDE AIR SEALS
3 - LOWER AIR SEAL
Fig. 25 Radiator
1 - OVERFLOW HOSE
2 - UPPER RADIATOR HOSE
3 - RADIATOR ASSEMBLY
PT
ENGINE - 1.6L SOHC
7 - 27
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) Install the lower air seal to radiator (Fig. 24).
(2) Position radiator into mounting position.
(3) Position A/C condenser against radiator. Hand
start lower fasteners.
(4) Install radiator fan/shroud assembly. Hand
start upper fasteners and remaining side fasteners
that hold AC condenser also.
(5) Raise vehicle on hoist.
(6) Connect the lower air seal to the side air seals
(Fig. 24).
(7) Install
two
remaining
lower
radiator
fan
shroud fasteners to radiator (Fig. 23). Torque fasten-
ers to 6 N·m (55 in. lbs.).
(8) Connect lower radiator hose. Align the hose
and position the clamp so it will not interfere with
engine components.
(9) Connect the radiator fan motor electrical con-
nector (Fig. 22).
(10) Close radiator draincock.
(11) Lower vehicle.
(12) Torque radiator fan shroud fasteners to 6 N·m
(55 in. lbs.).
(13) Torque AC condenser fasteners to 8 N·m (70
in. lbs.).
(14) Connect upper radiator hose and overflow
hose (Fig. 25). Align the upper radiator hose and
position the clamp to prevent interference with the
engine or hood.
(15) Install upper radiator closure panel (Refer to
23
-
BODY/EXTERIOR/RADIATOR
CLOSURE
PANEL - INSTALLATION).
(16) Install grille (Refer to 23 - BODY/EXTERIOR/
GRILLE - INSTALLATION).
(17) Connect negative battery cable.
(18) Fill cooling system with coolant (Refer to 7 -
COOLING/ENGINE - STANDARD PROCEDURE).
(19) Operate engine until it reaches normal oper-
ating temperature. Check cooling system for correct
fluid level and leaks.
HEATER RETURN TUBE
REMOVAL
(1) Disconnect negative battery cable.
(2) Disconnect positive battery cable.
(3) Remove battery.
(4) Drain cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(5) Remove fasteners securing heater return tube
to engine block and thermostat housing (Fig. 26).
(6) Raise vehicle on hoist.
(7) Remove clamp and disconnect heater hose from
water pump.
(8) Lower vehicle.
(9) Remove clamp and disconnect heater hose from
heater tube.
(10) Remove heater tube.
INSTALLATION
(1) Position heater tube in it’s mounting position
(Fig. 26).
(2) Connect heater hose to tube. Install clamp.
(3) Raise vehicle on hoist.
(4) Connect heater hose to water pump. Install
clamp.
(5) Lower vehicle.
(6) Install fasteners securing heater return tube to
engine block and thermostat housing.
(7) Install battery.
(8) Connect positive battery cable.
(9) Connect negative battery cable.
(10) Fill cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
Fig. 26 Heater Return Tube
1- HEATER RETURN TUBE
7 - 28
ENGINE - 1.6L SOHC
PT
RADIATOR (Continued)
WATER PUMP/POWER
STEERING PUMP ASSEMBLY
DESCRIPTION
The water pump on this vehicle is attached to the
rear of the power steering pump to form an assembly
(Fig. 27). The water pump/power steering pump
assembly is located on the front corner of the engine
(Fig. 29).
The water pump is bolted to the rear of the power
steering pump. Driven by the power steering pump
shaft, the water pump’s impeller is located inside a
die-cast aluminum housing. The water pump housing
has a built in outlet. The water pump also has a
bolt-on inlet cover with two ports, one for incoming
coolant from the radiator and the other for incoming
coolant from the heater.
Both pumps (water and power steering) can be ser-
viced separately. Remove the entire water pump/
power steering pump assembly, then disassemble it
to service either pump.
For information on the power steering pump,
(Refer to 19 - STEERING/PUMP - DESCRIPTION).
REMOVAL
NOTE: Before proceeding, review all Warnings and
Cautions (Refer to 7 - COOLING - WARNING) and
(Refer to 19 - STEERING - WARNING).
(1) Disconnect battery negative (-) terminal.
(2) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELT
-
REMOVAL).
(3) Remove power steering fluid reservoir. (Refer to
19 - STEERING/PUMP/RESERVOIR - REMOVAL)
(4) Remove generator. (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - REMOVAL)
(5) Drain engine coolant (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE - DRAIN
COOLING SYSTEM).
(6) If equipped with air conditioning, remove A/C
compressor upper mounting bolts.
(7) Raise
vehicle
(Refer
to
LUBRICATION
&
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(8) Remove accessory drive belt splash shield.
(9) If equipped with air conditioning, remove A/C
compressor lower mounting bolts. Reposition A/C
compressor to allow access to power steering pump/
water pump lower mounting bolts. Do not overextend
A/C hoses while performing this.
(10) Remove radiator hose at inlet to water pump.
(11) Remove heater tube hose at water pump.
(12) Lower vehicle.
(13) Remove the bolt fastening the power steering
pressure hose to the reservoir bracket (Fig. 28).
(14) Back out the tube nut securing the power
steering fluid pressure hose to the power steering
pump and remove the hose from the pump (Fig. 28).
Cap off hose end and pump pressure port.
(15) Remove coolant outlet connector hose at water
pump outlet.
(16) Remove all four power steering pump mount-
ing bolts. (Fig. 29)
(17) Remove power steering pump and water
pump as an assembly.
(18) To separate the power steering pump from the
water pump, (Refer to 7 - COOLING/ENGINE/WA-
TER PUMP - DISASSEMBLY).
(19) If the power steering pump pulley needs to be
removed, (Refer to 19 - STEERING/PUMP - DISAS-
SEMBLY).
Fig. 27 Water Pump/Power Steering Pump Assembly
1 - CONNECTOR
2 - COOLANT OUTLET CONNECTOR HOSE
3 - HEATER RETURN HOSE INLET
4 - COOLANT INLET
5 - WATER PUMP
6 - PUMP-TO-PUMP ATTACHING (HEX) BOLTS
7 - POWER STEERING PUMP
8 - POWER STEERING PUMP PRESSURE (OUTLET) PORT
9 - POWER STEERING PUMP SUPPLY (INLET) FITTING
PT
ENGINE - 1.6L SOHC
7 - 29
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