Chrysler PT Cruiser. Manual — part 453
ENGINE - 1.6L SOHC
DESCRIPTION
The cooling system consists of an engine cooling
module, thermostat, coolant, hoses, clamps, coolant
recovery container, and a water pump to circulate the
coolant. The engine cooling module may consist of a
radiator, electric fan, radiator pressure cap, transmis-
sion oil cooler and lines (auto transmission equipped
vehicles), and an air conditioning condenser (air con-
ditioning equipped vehicles).
OPERATION
The primary purpose of a cooling system is to
maintain engine temperature in a range that will
provide satisfactory engine performance and emission
levels under all expected driving conditions. It also
provides hot water (coolant) for heater performance
and cooling for automatic transmission oil. It does
this by transferring heat from engine metal to cool-
ant, moving this heated coolant to the radiator, and
then transferring this heat to the ambient air.
The coolant flow circuit is shown in (Fig. 1).
Fig. 1 Cooling System Operation
1 - HEATER CORE
2 - RADIATOR PRESSURE CAP
3 - COOL DOWN
4 - HEAT UP
5 - THERMOSTAT
6 - COOLANT RECOVERY CONTAINER
7 - RADIATOR
8 - WATER PUMP
9 - ENGINE
7 - 14
ENGINE - 1.6L SOHC
PT
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING SYSTEM
AERATION
If coolant level drops below a certain point, aera-
tion will occur drawing air into the water pump
resulting in the following:
• High reading shown on the temperature gauge.
• Loss of coolant flow through the heater core.
• Corrosion in the cooling system.
• Transmission oil will become hotter (automatic
transmission equipped vehicles).
• Water pump seal may run dry, increasing the
risk of premature seal failure.
• Combustion gas leaks into the coolant can also
cause the above problems.
DIAGNOSIS AND TESTING - COOLING SYSTEM
DEAERATION
As air is removed from the cooling system, it gath-
ers in the coolant recovery container. This pressure is
released into the atmosphere through the pressure
valve located in the radiator pressure cap when pres-
sure reaches 96 - 124 kPa (14 - 18 psi). This air is
replaced with coolant from the coolant recovery con-
tainer.
NOTE: Deaeration does not occur at engine idle,
higher engine speeds are required. Normal driving
will deaerate cooling system.
To effectively deaerate the system, multiple ther-
mal cycles of the system may be required.
DIAGNOSIS AND TESTING - COOLING SYSTEM
FLOW CHECK
WARNING: DO NOT REMOVE THE COOLING SYS-
TEM PRESSURE CAP WITH THE SYSTEM HOT AND
UNDER PRESSURE BECAUSE SERIOUS BURNS
FROM COOLANT CAN OCCUR.
To determine whether coolant is flowing through
the cooling system, use one of the following proce-
dures:
• If engine is cold, idle engine until normal oper-
ating temperature is reached. Then feel the upper
radiator hose. If it is hot, coolant is circulating.
• 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.
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 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.
With engine not running, wipe the coolant filler
neck sealing seat clean. The radiator should be full.
Attach a cooling system pressure tester (Tool 7700
or equivalent) to the coolant filler neck, as shown in
(Fig. 2) and apply 104 kPa (15 psi) pressure. If the
pressure drops more than 2 psi in 2 minutes inspect
all points for external leaks.
All hoses, radiator and heater, should be moved
while at 104 kPa (15 psi) since some leaks occur
while driving due to engine movement, etc.
Fig. 2 Pressure Testing Cooling System
1 - PRESSURE TESTER
PT
ENGINE - 1.6L SOHC
7 - 15
ENGINE - 1.6L SOHC (Continued)
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.
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. 3).
(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).
Fig. 3 Cooling System
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ENGINE - 1.6L SOHC
PT
ENGINE - 1.6L SOHC (Continued)
(1) Close radiator draincock. Hand tighten only.
(2) Remove cooling system pressure cap. Install
Special Tool 8195 Filling Aid Funnel (Fig. 4).
(3) Use the supplied clip to pinch overflow hose
that connects between the radiator and the coolant
recovery container (Fig. 4).
(4) Place a piece of clear 6.35 mm (0.250 in.) I.D.
tubing 305 mm (12 in.) long over the cooling system
bleed screw nipple. The cooling system bleed screw is
located in the heater hose near the coolant recovery
container (Fig. 5).
(5) Open, but do not remove, the cooling system
bleed screw.
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 small col-
umn of coolant begins to fill the clear plastic tube on
the bleed screw.
(7) Close the cooling system bleed screw and
remove the tubing.
(8) Remove clip from overflow hose and remove
funnel 8195.
(9) Install cooling system pressure cap.
(10) Slowly fill the coolant recovery container to
the FULL HOT mark with the recommended coolant.
It may be necessary to add coolant to the recovery
container after one warm-up/cool down cycle in order
to maintain the 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.
Fig. 4 Filling the Cooling System
1 - SPECIAL TOOL 8195 FILLING AID FUNNEL
2 - PINCH OVERFLOW HOSE
Fig. 5 Cooling System Bleed Screw
1 - COOLING SYSTEM BLEED SCREW
2 - HEATER HOSE
PT
ENGINE - 1.6L SOHC
7 - 17
ENGINE - 1.6L SOHC (Continued)
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