Chrysler PT Cruiser. Manual — part 452
Fig. 4 Power Steering/Air Conditioning Belt
1 - POWER STEERING PUMP PULLEY
2 - POWER STEERING PUMP PULLEY
3 - AIR CONDITIONING COMPRESSOR PULLEY
4 - CRANKSHAFT PULLEY
5 - BELT
6 - IDLER PULLEY
7 - CRANKSHAFT PULLEY
8 - BELT
Fig. 5 Generator Belt
1 - ADJUSTING BOLT
2 - LOCKING NUT
3 - PIVOT BOLT
Fig. 6 Drive Belt Wear Pattern
1 - NORMAL CRACKS - BELT OK
2 - NOT NORMAL CRACKS - REPLACE BELT
7 - 10
ACCESSORY DRIVE - 2.0/2.4L DOHC
PT
DRIVE BELTS (Continued)
INSTALLATION
GENERATOR BELT
NOTE: When installing drive belt onto pulleys, make
sure that belt is properly routed and all V-grooves
make proper contact with pulley grooves.
(1) Install belt and/or adjust belt tension by tight-
ening adjusting bolt. Adjust belt to specification
shown in Belt Tension Chart.
(2) Check belt tension using Special Tool 8371 –
Belt Tension Gauge Adapter, and the DRBIII
t using
the following procedures:
WARNING: DO NOT CHECK BELT TENSION WITH
ENGINE RUNNING.
(a) Connect 8371 to the DRBIII
t following the
instructions provided in tool kit.
(b) Place end of microphone probe approximately
2.54 cm (1 in.) from belt at one of the belt center
span locations shown in (Fig. 7).
(c) Pluck the belt a minimum of 3 times. (Use
your finger or other suitable object)
(d) The frequency of the belt in hertz (Hz) will
display on DRBIII
t screen.
(e) Adjust belt to obtain proper frequency (ten-
sion). Refer to the belt tension chart for specifica-
tions.
(3) Tighten pivot bolt to 54 N·m (40 ft. lbs.) and
locking nut to 54 N·m (40 ft. lbs.) (Fig. 5).
(4) Install power steering pump/air conditioning
compressor drive belt.
BELT TENSION CHART
Accessory
Drive Belt
Belt Tension
Power Steering
Pump and A/C
Compressor
Dynamic Tensioner
Generator
New 135 lb.
235-247 Hz
Used 100 lb.
207-217 Hz
POWER STEERING PUMP/AIR CONDITIONING
COMPRESSOR BELT
NOTE: When installing drive belt onto pulleys, make
sure that belt is properly routed and all V-grooves
make proper contact with pulley grooves.
(1) Install belt (Fig. 4) over all pulleys except for
the power steering pump pulley.
(2) Using a wrench, rotate belt tensioner clockwise
(Fig. 3) until belt can be installed onto power steer-
ing pump pulley. Release spring tension onto belt.
(3) After belt is installed, inspect belt length indi-
cator marks (Fig. 8). The indicator mark should be
within the minimum belt length and maximum belt
length marks. On a new belt, the indicator mark
should align approximately with the nominal belt
length mark.
(4) Install belt splash shield (Fig. 2).
Fig. 7 Belt Center Span
Fig. 8 Belt Length Indicator Marks
1 - BELT LENGTH INDICATOR
2 - MAXIMUM LENGTH
3 - NOMINAL LENGTH
4 - TENSIONER
5 - MINIMUM LENGTH
PT
ACCESSORY DRIVE - 2.0/2.4L DOHC
7 - 11
DRIVE BELTS (Continued)
ADJUSTMENTS
BELT TENSION
For belt tension adjustment procedure, (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
AUTOMATIC BELT TENSIONER
AND PULLEY
DESCRIPTION
The automatic belt tensioner (Fig. 9) maintains
proper tension on the power steering and air condi-
tioning belt. The tensioner pulley can be serviced
separately.
NOTE: Tensioner arm should move freely and main-
tain 33–46 lb. tension on belt.
REMOVAL
(1) Remove power steering/air conditioning com-
pressor belt (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - REMOVAL).
(2) Remove tensioner mounting bolt and remove
tensioner assembly (Fig. 9).
(3) Remove tensioner pulley, if replacing the pul-
ley.
INSTALLATION
(1) Install tensioner pulley and bolt, if removed.
Tighten bolt to 27 N·m (20 ft. lbs.).
(2) Install
tensioner
assembly
to
engine
and
tighten bolt to 54 N·m (40 ft. lbs.) (Fig. 9).
(3) Install power steering/air conditioning compres-
sor
belt
(Refer
to
7
-
COOLING/ACCESSORY
DRIVE/DRIVE BELTS - INSTALLATION).
NOTE: Tensioner arm should move freely and main-
tain 33–46 lb. tension on belt.
Fig. 9 Automatic Belt Tensioner
1 - TORQUE STRUT BRACKET
2 - BOLT
3 - AUTOMATIC BELT TENSIONER ASSEMBLY
7 - 12
ACCESSORY DRIVE - 2.0/2.4L DOHC
PT
DRIVE BELTS (Continued)
ENGINE - 1.6L SOHC
TABLE OF CONTENTS
page
page
ENGINE - 1.6L SOHC
. . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIAGNOSIS AND TESTING - COOLING
SYSTEM AERATION . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - COOLING
SYSTEM DEAERATION . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - COOLING
SYSTEM FLOW CHECK . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - COOLING
SYSTEM LEAK TESTING . . . . . . . . . . . . . . . . 15
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . 16
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
. . . . . . . . . . . . . . . . . . . . . . . . . . 17
COOLANT
. . . . . . . . . . . . . . . . . . . . . . . . . 18
DIAGNOSIS AND TESTING - COOLANT
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
COOLANT LEVEL CHECK . . . . . . . . . . . . . . . 18
ADDITIONAL COOLANT . . . . . . . . . . . . . . . . . 19
HOSE CLAMPS
COOLANT RECOVERY CONTAINER
. . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . . . . . 20
ENGINE BLOCK HEATER
. . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DIAGNOSIS AND TESTING - ENGINE BLOCK
. . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . . . . . 21
ENGINE COOLANT TEMP SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . . . . . . . . . 21
ENGINE COOLANT THERMOSTAT AND
HOUSING
REMOVAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . . . . 22
RADIATOR PRESSURE CAP
. . . . . . . . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DIAGNOSIS AND TESTING - COOLING
SYSTEM PRESSURE CAP TESTING . . . . . . . 22
DIAGNOSIS AND TESTING - COOLING
SYSTEM PRESSURE RELIEF TESTING . . . . 23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . . . . . . . . 23
RADIATOR DRAINCOCK
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . 24
RADIATOR FAN
. . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DIAGNOSIS AND TESTING - RADIATOR FAN
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . 26
RADIATOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
. . . . . . . . . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . . . . . . . . . 28
HEATER RETURN TUBE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . . . . . . . . . 28
WATER PUMP/POWER STEERING PUMP
ASSEMBLY
DESCRIPTION
. . . . . . . . . . . . . . . . . . . . . . . . . 29
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
. . . . . . . . . . . . . . . . . . . . . . . . . 30
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
. . . . . . . . . . . . . . . . . . . . . . . . . 31
PT
ENGINE - 1.6L SOHC
7 - 13
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