Chrysler PT Cruiser. Manual — part 441
2.2L DIESEL/2.4L TURBO MODELS
(1) Verify fluid level in brake master cylinder. Top
off with DOT 3 brake fluid as necessary. Leave cap
off.
(2) Raise vehicle on hoist.
(3) Remove bleed port protective cap, and install
suitable size and length of clear hose (Fig. 7) to mon-
itor and divert fluid into suitable container.
(4) Release only the lower hydraulic tube snap
ring, pull outward on tube until it stops against the
second ring, opening up the bleed circuit and starting
the air purge and fluid fill process (Fig. 7).
(5) Lower vehicle, but only enough to gain access
to and fill the brake master cylinder.
NOTE: Do not allow clutch master cylinder to run
dry while fluid exits bleed port. If master cylinder
runs dry, it is necessary to remove clutch master
cylinder, position vertically (with pushrod down) for
10 seconds, and reinstall.
(6) Top off brake master cylinder fluid level while
air is purged and fluid drains from bleed port. Con-
tinue this until no air bubbles are seen and a solid
column of fluid exists.
(7) Close hydraulic bleed circuit. Insert hydraulic
pipe fully into slave cylinder and depress retaining
ring so both are closed, securing tube (Fig. 8).
Remove drain hose. Pull outward to verify connec-
tion.
(8) From driver’s seat, actuate clutch pedal 60–100
times.
(9) Apply parking brake. Start engine and verify
clutch operation and pedal feel. If pedal feels fine
and clutch operates as designed, stop here. If pedal
still feels spongy or clutch does not fully disengage,
excessive air is still trapped within the system most
likely at the master cylinder.
(10) Remove clutch master cylinder body from
dash panel or pedal bracket. Position cylinder body
vertical (pushrod pointing down) for 10 seconds. Air
bubbles will be seen escaping master cylinder.
(11) Verify clutch operation. Repeat procedure if
necessary.
(12) Top off brake master cylinder fluid level with
DOT 3 brake fluid as necessary.
Fig. 7 Opening Hydraulic Circuit Bleed Port
1 - CLEAR HOSE
2 - HYDRAULIC TUBE
3 - RETAINER RING
Fig. 8 Hydraulic Tube Retaining Clips
1 - RETAINER CLIPS
6 - 8
CLUTCH
PT
CLUTCH (Continued)
SPECIFICATIONS
CLUTCH/HYDRAULICS/PEDALS
TORQUE SPECIFICATIONS
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Brake/Clutch Pedal & Booster-to-Dash Nuts
34
—
300
Brake/Clutch Pedal Assembly-to-Instrument Panel
34
—
300
Clutch Cover-to-Flywheel Bolts
29
—
250
Clutch Pedal Pivot Shaft Nut
42
31
—
Damper-to-Transaxle Nuts
24
—
215
Driveplate-to-Crankshaft Bolts
95
70
—
Flywheel-to-Crankshaft Bolts
95
70
—
Master Cylinder Pushrod Adj. Screw (LHD Models)
6
—
55
Modular Clutch-to-Drive Plate Bolts
88
65
—
Master Cylinder Mounting Nuts (LHD)
15
—
130
Master Cylinder Reservoir Mounting bolts (LHD)
11
—
115
Master Cylinder Reservior Mounting Screw (RHD)
3
—
24
Slave Cylinder-to-Transaxle (2.0/2.4L Models)
12
—
105
Slave Cylinder-to-Transaxle (2.0/2.4L Models)
19
—
168
Transaxle-to-Engine Mounting Bolts
95
70
—
SPECIAL TOOLS
HYDRAULIC CLUTCH
Clutch Disc Alignment Tool - 6724
PT
CLUTCH
6 - 9
CLUTCH (Continued)
CLUTCH DISC AND PRESSURE
PLATE
REMOVAL
REMOVAL—1.6L
(1) Remove transaxle. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL - REMOVAL)
(2) Mark position of pressure plate on flywheel
with paint or a scriber for assembly reference.
(3) Loosen and remove six (6) pressure plate-to-fly-
wheel bolts. Remove pressure plate and clutch disc
(Fig. 9).
(4) Remove eight (8) flywheel-to-crankshaft bolts
and remove flywheel (Fig. 10).
(5) Inspect release lever and bearing (Fig. 11).
Replace as necessary. (Refer to 6 - CLUTCH/
CLUTCH RELEASE BEARING - REMOVAL)
Fig. 9 Clutch Disc and Pressure Plate
1 - FLYWHEEL
2 - CLUTCH DISC
3 - PRESSURE PLATE
4 - BOLT (6)
Fig. 10 Flywheel-to-Crankshaft
1 - FLYWHEEL
2 - BOLT (8)
3 - CRANKSHAFT FLANGE
Fig. 11 Release Bearing and Lever
1 - RELEASE BEARING
2 - LEVER
6 - 10
CLUTCH
PT
REMOVAL—2.2L TD
(1) Remove transaxle assembly. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL
-
REMOVAL)
(2) Mark position of pressure plate on flywheel
with paint or a scriber for assembly reference.
(3) Loosen and remove six (6) pressure plate-to-fly-
wheel bolts. Remove pressure plate and clutch disc
(Fig. 12).
(4) Remove eight (8) flywheel-to-crankshaft bolts
and remove flywheel assembly (Fig. 13).
INSTALLATION
INSTALLATION—1.6L
(1) Inspect clutch release bearing and lever for
excessive wear and replace as necessary (Fig. 11).
(2) Clean the surfaces of the flywheel and pressure
plate to make certain that all oil, grease, and rust
have been removed.
(3) Verify the crankshaft mounting flange is free of
debris, oil, grease, etc. Position the flywheel onto the
engine crankshaft (Fig. 10).
(4) Install and torque the flywheel-to-crankshaft
bolts to 95 N·m (70 ft.lbs.).
(5) Apply a very light coating of grease to the
splines in the clutch disc hub.
(6) Position the clutch disc to the flywheel. Make
sure the side marked “FLYWHEEL SIDE” faces the
flywheel.
(7) Install the clutch pressure plate to the flywheel
and clutch disc (Fig. 9). Finger tighten the six (6)
pressure plate-to-flywheel bolts.
(8) Use Clutch Alignment Tool 6724 to position the
clutch disc to the center of the flywheel (Fig. 14).
(9) Tighten pressure plate bolts evenly and in rota-
tion a few threads at a time The bolts must be
tightened evenly and to specified torque to
avoid distorting the pressure plate..
Fig. 12 Clutch Disc and Pressure Plate
1 - FLYWHEEL (DUAL-MASS)
2 - CLUTCH DISC
3 - PRESSURE PLATE
Fig. 13 Flywheel-to-Crankshaft Bolt Pattern
1 - FLYWHEEL ASSEMBLY
Fig. 14 Aligning Clutch Disc—Typical
1 - FLYWHEEL
2 - PRESSURE PLATE
3 - CLUTCH DISC ALIGNMENT TOOL
PT
CLUTCH
6 - 11
CLUTCH DISC AND PRESSURE PLATE (Continued)
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