Chrysler PT Cruiser. Manual — part 439
(7) Install the ICU in the vehicle. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ICU
(INTE-
GRATED CONTROL UNIT) - INSTALLATION)
INSTALLATION
(1) Place the ICU and mounting bracket into the
engine compartment, inserting bracket hooks into
hanger holes in body frame rail (Fig. 37).
(2) Install the front mounting screw attaching the
ICU mounting bracket to the body (Fig. 37). Do not
tighten screw at this time.
(3) Raise
and
support
the
vehicle.
(Refer
to
LUBRICATION
&
MAINTENANCE/HOISTING
-
STANDARD PROCEDURE)
(4) Install the two rear mounting screws attaching
the ICU mounting bracket to the body (Fig. 37).
Tighten both screws to 23 N·m (200 in. lbs.) torque.
(5) Lower the vehicle.
(6) Tighten the front mounting screw attaching the
ICU mounting bracket to the body (Fig. 37) to 23
N·m (200 in. lbs.) torque.
CAUTION: Before installing the 47-way connector
on the ABM, be sure the seal is properly installed in
the connector.
(7) Install the 47-way wiring connector into the
socket of the ABM and close the cover (Fig. 36), lock-
ing the connector in place.
(8) Install the four chassis brake tubes going to
the wheel brakes into their respective outlet ports on
the ICU HCU (Fig. 32) (Fig. 33) (Fig. 34). Using a
crow foot wrench on a torque wrench, tighten the
four tube nuts to 17 N·m (145 in. lbs.) torque.
(9) Install the primary and secondary brake tubes
from the master cylinder into the HCU ports (Fig.
32) (Fig. 33). Using a crow foot wrench on a torque
wrench, tighten the tube nuts to 17 N·m (145 in. lbs.)
torque.
(10) Position the power distribution center and
bracket back into place and install the mounting
bolts (Fig. 30) (Fig. 31).
(11) Connect the wiring connector to the brake
fluid level switch (Fig. 29).
(12) Install the battery. (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION)
(13) Install the air cleaner housing.
(14) Install the air cleaner cover.
(15) Hook up the scan tool to initialize the new
ABM. Clear any faults and perform verification test.
(16) Fill the master cylinder to the proper fill level
and bleed the base and ABS hydraulic systems.
(Refer to 5 - BRAKES - ABS - STANDARD PROCE-
DURE)
(17) Road test the vehicle to ensure proper opera-
tion of the base and antilock brake systems.
5 - 108
BRAKES - ABS
PT
INTEGRATED CONTROL UNIT (ICU) - MK25E (Continued)
CLUTCH
TABLE OF CONTENTS
page
page
CLUTCH
. . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - CLUTCH
CHATTER COMPLAINTS . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING - DRIVE PLATE
MISALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING - CLASH-INTO-
REVERSE COMPLAINTS . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . 9
CLUTCH DISC AND PRESSURE PLATE
. . . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . . . 11
. . . . . . . . . . . . . . . . . . 11
. . . . . . . . . . . . . . . . 12
CLUTCH INTERLOCK/UPSTOP SWITCH
. . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
. . . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . . . . . . . . . . . . . . . . 17
. . . . . . . . . . . . . . . . . . 17
. . . . . . . . . . . . . . . . . . 18
CLUTCH RELEASE BEARING
. . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . 20
FLYWHEEL
. . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . . . . 22
MASTER CYLINDER - LHD
. . . . . . . . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . . . . . . . 26
MASTER CYLINDER - RHD
. . . . . . . . . . . . . . . . . . . . . . . . . 29
. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
. . . . . . . . . . . . . . . . . . . . . . . . . 32
MODULAR CLUTCH
. . . . . . . . . . . . . . . . . . . . . . . . . 36
. . . . . . . . . . . . . . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . . . . . . . . . . . 39
SLAVE CYLINDER
. . . . . . . . . . . . . . . . . . . . . . . . . 39
REMOVAL—1.6/2.4L (Except Diesel and
Turbo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
REMOVAL—DIESEL AND TURBO MODELS
INSTALLATION—1.6/2.4L MODELS (Except
Diesel and Turbo) . . . . . . . . . . . . . . . . . . . . . . 41
MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
PT
CLUTCH
6 - 1
CLUTCH
DESCRIPTION
The typical clutch hydraulic system consists of a
clutch master cylinder, slave cylinder, and an inter-
connecting fluid line (Fig. 1) (Fig. 2). Clutch hydrau-
lic fluid is supplied by the brake system via the
brake master cylinder reservoir. LHD models have an
adjustable pedal pushrod.
FLUID
CAUTION: Never use any type of petroleum-based
fluid (engine oil, transmission oil, power steering
fluid, etc.) in the clutch hydraulic system. Use of
such fluids will result in master/slave cylinder seal
damage, and cause a failure of the hydraulic clutch
release system.
NOTE: Under normal operating conditions, the
clutch hydraulic system does not require additional
fluid for the life of the vehicle. Since the clutch
shares the brake reservoir, the fluid level will be
maintained whenever the brake system is checked.
The fluid required for use in the clutch hydraulic
system is brake fluid conforming to DOT 3 specifica-
tions and J1703 standards. No other type of fluid is
recommended or approved for use in the clutch
hydraulic system. use only Mopar
t brake fluid or
equivalent from a tightly sealed container.
OPERATION
T350-Equipped Models
The clutch hydraulic system is responsible for
engaging and disengaging the clutch. Depressing the
clutch pedal develops fluid pressure in the clutch
master cylinder. This pressure is transmitted to the
slave cylinder through a connecting line. In turn, the
slave cylinder operates the clutch release lever (Fig.
1) (Fig. 2).
Slave cylinder spring force causes the release lever
to hold the release bearing in contact with the dia-
phragm spring, also known as bearing preload. Dur-
ing a clutch pedal actuation, the hydraulic fluid
Fig. 1 LHD Clutch Hydraulic System—Typical
1 - BRAKE MASTER CYLINDER RESERVOIR
2 - CLUTCH MASTER CYLINDER
3 - PEDAL ASSEMBLY
4 - ADJUSTMENT SCREW
5 - SLAVE CYLINDER
Fig. 2 RHD Clutch Hydraulic System—Typical
1 - BRAKE MASTER CYLINDER RESERVOIR
2 - MASTER CYLINDER
3 - PEDAL ASSEMBLY
4 - SLAVE CYLINDER
6 - 2
CLUTCH
PT
pressure applies additional force to the release lever.
As additional force is applied, the bearing presses the
diaphragm spring fingers inward on the fulcrums.
This action moves the pressure plate rearward,
relieving clamp force on the disc.
G288-Equipped Models
The clutch hydraulic system is responsible for
engaging and disengaging the clutch. Depressing the
clutch pedal develops fluid pressure in the clutch
master cylinder. This pressure is transmitted to the
slave cylinder through a connecting line.
Slave cylinder force transmits through the integral
release bearing, which is in contact with the pressure
plate
diaphragm
spring. As
additional
force
is
applied, the bearing depresses the diaphragm spring
fingers inward on the fulcrums. The action moves the
pressure plate rearward, relieving clamping force on
the clutch disc.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING—CLUTCH SYSTEM
DIAGNOSIS
Clutch problem diagnosis will generally require a
road test to determine the type of fault. Component
inspection will then determine the problem after road
testing.
Drive the vehicle at normal speeds during road
test. Shift the transaxle through all gear ranges and
observe clutch action. If chatter, grab, slip, or
improper release is experienced, remove and inspect
the clutch components. If the problem is noise or
hard shifting, further diagnosis may be needed. The
transaxle or other driveline components may actually
be at fault.
SERVICE DIAGNOSIS - CLUTCH GRAB/CHATTER
CONDITION
POSSIBLE CAUSES
CORRECTION
CLUTCH DISC FACING
COVERED WITH OIL OR
GREASE
Oil leak at engine rear main or
transaxle input shaft seal.
2.4L - Correct leak and replace modular
clutch assembly.
1.6L/Diesel/Turbo - Clean pressure plate,
flywheel, and replace clutch disc.
Too much grease applied to splines
of disc and input shaft.
Apply lighter coating of grease to splines.
NO FAULT FOUND WITH
CLUTCH
COMPONENTS
Problem actually related to
suspension or driveline component.
Further diagnosis required. Check
engine/transmission mounts, suspension
attaching parts and other driveline
components as needed.
Engine related problems.
Check EFI and ignition systems.
PARTIAL ENGAGEMENT
OF CLUTCH DISC
Clutch cover, spring, or release
fingers bent, distorted (rough
handling, improper assembly).
Replace clutch assembly.
Clutch disc damaged or distorted.
Replace clutch assembly.
Clutch misalignment.
2.4L and Turbo - Verify modular clutch pilot
plate alignment to crankshaft. Replace the
modular clutch assembly if the pilot plate is
loose or bent.
1.6L and Diesel - Check alignment and
runout of flywheel, disc, or cover. Check
clutch housing to engine dowels and dowel
holes for damage. Correct as necessary.
PT
CLUTCH
6 - 3
CLUTCH (Continued)
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