Chrysler PT Cruiser. Manual — part 754
(5) Unscrew and remove the power steering fluid
pressure switch from the power steering gear.
INSTALLATION
(1) By hand, screw the power steering pressure
switch into the power steering gear until it is fully
seated (Fig. 15). Tighten the power steering pressure
switch to a maximum torque of 8 N·m (70 in. lbs.).
Over-torquing will result in stripping the threads out
of the power steering pressure switch port in the
steering gear.
(2) Install the vehicle wiring harness connector. Be
sure the latch on the wiring harness connector is
fully engaged with the locking tab on the power
steering pressure switch.
(3) Lower the vehicle.
(4) Fill the power steering fluid reservoir to the
correct fluid level. (Refer to 19 - STEERING/PUMP/
FLUID - STANDARD PROCEDURE)
(5) Connect the negative cable to the negative post
of the battery.
(6) Start the engine and turn the steering wheel
several times stop-to-stop to bleed any air from the
fluid in the power steering system. Stop the engine,
check the fluid level, and inspect the system for
leaks.
TIE ROD - OUTER
REMOVAL
(1) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove the tire and wheel assembly from the
vehicle. (Refer to 22 - TIRES/WHEELS - REMOVAL)
(3) Loosen tie rod jam nut (Fig. 16). Thread the
jam nut far enough up the inner tie rod to pull the
collar away from the outer tie rod end. Pull the collar
off the end of the outer tie rod.
(4) Remove the nut attaching the outer tie rod end
to steering knuckle (Fig. 17). Remove the nut by
holding the tie rod stud stationary while loosening
and removing the nut with a wrench.
(5) Remove the outer tie rod from the steering
knuckle using Remover, Special Tool MB991113 (Fig.
18).
(6) Remove the tie rod heat shield.
(7) Remove the outer tie rod from the inner tie rod
by unthreading it.
Fig. 16 Outer Tie Rod
1 - INNER TIE ROD
2 - OUTER TIE ROD JAM NUT
3 - STEERING KNUCKLE
4 - OUTER TIE ROD END
5 - COLLAR
6 - INNER TIE ROD SERRATION
Fig. 17 Tools On Outer Tie Rod Nut
1 - OUTER TIE ROD
2 - STUD
3 - NUT
19 - 34
GEAR
PT
POWER STEERING PRESSURE SWITCH (Continued)
INSTALLATION
(1) Install the jam nut on the inner tie rod threads
if it is not already installed (Fig. 16).
NOTE: Be sure the collar is installed on the inner
tie rod with the flat end of the collar against jam nut
and the open end of the collar facing the outer tie
rod end.
(2) Install the collar on the inner tie rod (Fig. 16).
(3) Thread the outer tie rod onto the inner tie rod.
(4) Position the collar around the end of the outer
tie rod (Fig. 16).
(5) Thread the jam nut down the inner tie rod far
enough to hold the collar in place on the outer tie
rod. Do not tighten the jam nut.
(6) 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 outside of
the shield with the outside configuration of the steer-
ing arm. The shield should now be facing outboard,
away from the power steering gear and tie rod (Fig.
17).
(7) Attach the outer tie rod end to the steering
knuckle.
(8) Start the attaching nut onto the stud of the
outer tie rod.
(9) While holding the stud of the tie rod stationary
with a wrench, tighten the attaching nut (Fig. 17).
(10) Using a crowfoot wrench attached to a torque
wrench, tighten the attaching nut to 54 N·m (40 ft.
lbs.).
(11) Install the tire and wheel assembly(Refer to
22 - TIRES/WHEELS - INSTALLATION). Tighten
wheel nut to a torque of 135 N·m (100 ft. lbs.).
(12) Lower the vehicle.
(13) Adjust the front toe setting on the vehicle.
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE).
Fig. 18 Tie Rod Removal From Knuckle
1 - OUTER TIE ROD
2 - STEERING KNUCKLE
PT
GEAR
19 - 35
TIE ROD - OUTER (Continued)
PUMP
TABLE OF CONTENTS
page
page
PUMP
DESCRIPTION - 2.0L/2.4L/2.4L TURBO
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
STEERING PUMP INITIAL OPERATION
. . . . . . . . . . . . . . . 38
. . . . . . . . . . . . . . . . 41
. . . . . . . . . . . . . . . . 42
. . . . . . . . . . . . . . . . . . . . . . . . . 43
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION - 2.0L/2.4L ENGINE
FLUID
FLUID COOLER
. . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION - NON-TURBO ENGINES
HOSE - POWER STEERING PRESSURE
. . . . . . . . . . . . . . . 46
. . . . . . . . . . . . . . . 47
. . . . . . . . . . . . . . . . 49
HOSE - POWER STEERING PRESSURE/
RETURN
REMOVAL - 2.4L TURBO
. . . . . . . . . . . . . . . . . 52
. . . . . . . . . . . . . . 55
HOSE - POWER STEERING RETURN
. . . . . . . . . . . . . . . . 57
. . . . . . . . . . . . . . . . 57
INSTALLATION - 2.0L/2.4L ENGINE
HOSE - POWER STEERING SUPPLY
. . . . . . . . . . . . . . . . 60
INSTALLATION - 2.0L/2.4L ENGINE
PULLEY
. . . . . . . . . . . . . . . . . 61
. . . . . . . . . . . . . . 61
RESERVOIR
. . . . . . . . . . . . . . . . . . . . . . . . . 62
. . . . . . . . . . . . . . . 62
. . . . . . . . . . . . . . . . 63
INSTALLATION - 2.0L/2.4L ENGINE
PUMP
DESCRIPTION
DESCRIPTION - 1.6L ENGINE
Hydraulic pressure for operation of the power
steering gear is provided by a constant flow rate and
displacement vane-type power steering pump. The
pump is located on the front corner of the engine. It
is attached to the engine water (coolant) pump to
form an assembly (Fig. 1).
The power steering pump is belt driven. Its pulley
driven shaft traverses the length of the pump, exit-
ing the rear, driving the engine water pump that is
attached to the rear of the pump.
Both pumps can be serviced separately. The entire
power steering pump/water pump assembly must be
removed as an assembly, then disassembled to ser-
vice either pump. No repair procedures are to be
done on the internal components of the power steer-
ing pump itself. The pulley may be serviced sepa-
rately.
19 - 36
PUMP
PT
DESCRIPTION - 2.0L/2.4L/2.4L TURBO
ENGINE
The hydraulic pressure for operation of the power
steering gear is provided by a belt-driven power
steering pump (Fig. 2) (Fig. 3). The power steering
pump is a constant flow rate and displacement vane-
type pump.
The power steering pump for non-turbocharged
engines consists of the power steering pump and the
power steering pump pulley. The power steering fluid
reservoir is remotely located on this vehicle.
The power steering pump for turbocharged engines
consists of the power steering pump, the reservoir
mounted to the top, and the power steering pump
pulley.
No repair procedures are to be done on the internal
components of the power steering pump. On turbo-
charged engine applications, the reservoir is serviced
with the pump.
DESCRIPTION - 2.2L DIESEL
Hydraulic pressure for operation of the power
steering gear is provided by a constant flow rate and
displacement vane-type power steering pump. The
pump is located on the front corner of the engine. It
is attached to the engine water (coolant) pump to
form an assembly.
The power steering pump is belt driven. Its pulley
driven shaft traverses the length of the pump, exit-
ing the rear, driving the engine water pump that is
attached to the rear of the pump.
The power steering pump and water pump are ser-
viced as one assembly. The pulley may be serviced
separately.
STANDARD PROCEDURE - POWER STEERING
PUMP INITIAL OPERATION
WARNING:
THE
FLUID
LEVEL
SHOULD
BE
CHECKED AND ADJUSTED WITH THE ENGINE OFF
TO PREVENT INJURY FROM MOVING ENGINE COM-
PONENTS.
Fig. 1 Power Steering Pump/Water Pump Assembly
- 1.6L Engine
1 - OUTLET HOSE CONNECTOR FITTING BOLT (2)
2 - WATER PUMP
3 - POWER STEERING PUMP MOUNTING BOLT (4)
4 - POWER STEERING PUMP
Fig. 2 Power Steering Pump - 2.4L Engine
1 - SHAFT
2 - SUPPLY FITTING
3 - PRESSURE FITTING
Fig. 3 Power Steering Pump - 2.4L Turbo
1 - RESERVOIR
2 - RETURN FITTING
3 - PRESSURE FITTING
PT
PUMP
19 - 37
PUMP (Continued)
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