Chrysler PT Cruiser. Manual — part 761
RESERVOIR
DESCRIPTION
The power steering reservoir used on 1.6L engines
is mounted above the generator (Fig. 61). The power
steering fluid reservoir for 2.0L and 2.4L non-turbo
engines is mounted above the engine head cover and
is attached to the backside of the engine (Fig. 62).
The 2.2L Diesel uses a power steering reservoir that
is mounted above the transaxle bell housing (Fig.
64).
The 2.4L turbo engine uses a power steering reser-
voir that is attached to the power steering pump. The
reservoir is serviced with the pump.
REMOVAL
REMOVAL - 1.6L ENGINE
(1) Remove the filler cap from remote power steer-
ing fluid reservoir.
(2) Siphon as much fluid as possible from the fluid
reservoir.
Fig. 61 Hoses, Reservoir And Pump - 1.6L Engine
1 - RETURN HOSE
2 - FLUID RESERVOIR
3 - SUPPLY HOSE
4 - 1.6L ENGINE
5 - COOLER OUTLET TUBE
6 - PRESSURE HOSE
Fig. 60 Pump Pulley Mounting
1 - PULLEY MOUNTING BOLTS
2 - RIGHT FRAME RAIL
3 - PRESSURE HOSE FITTING
4 - PULLEY
19 - 62
PUMP
PT
PULLEY (Continued)
(3) Remove the clamp attaching the return hose to
the power steering fluid reservoir. Disconnect hose
from reservoir (Fig. 61).
(4) Remove the clamp attaching the supply hose to
the power steering fluid reservoir. Disconnect hose
from reservoir (Fig. 61).
(5) Press the tang on the reservoir mounting
bracket retaining the reservoir to the bracket, then
pull upward on reservoir and remove it from the
bracket.
REMOVAL - 2.0L/2.4L ENGINE
NOTE: Before proceeding, (Refer to 19 - STEERING
- WARNING).
(1) Remove the filler cap from remote power steer-
ing fluid reservoir (Fig. 62).
(2) Siphon as much fluid as possible from the fluid
reservoir.
(3) Remove the plastic engine cover.
(4) Remove the clamp attaching the supply hose to
the power steering fluid reservoir (Fig. 62). Remove
the hose from the reservoir.
(5) Remove the clamp attaching the return hose to
the power steering fluid reservoir (Fig. 62). Remove
the hose from the reservoir.
(6) Remove the 2 bolts fastening the reservoir to
the rear of the engine (Fig. 63)
REMOVAL - 2.2L DIESEL
NOTE: Before proceeding, (Refer to 19 - STEERING
- WARNING).
(1) Remove engine top appearance cover (Fig. 57).
(2) Remove engine air cleaner. (Refer to 9 -
ENGINE/AIR
INTAKE
SYSTEM/AIR
CLEANER
HOUSING - REMOVAL)
(3) Siphon as much fluid as possible from power
steering fluid reservoir.
(4) Remove hose clamp securing return hose to
fluid reservoir fitting (Fig. 51). Slide hose off end of
reservoir fitting.
(5) Remove hose clamp securing supply hose to
fluid reservoir fitting (Fig. 58). Slide hose off end of
reservoir fitting.
(6) Remove mounting bolts used to secure reser-
voir in place (Fig. 64). Remove reservoir.
Fig. 62 Hose Connection At Reservoir
1 - POWER STEERING FLUID RESERVOIR
2 - ENGINE COVER
3 - SUPPLY HOSE
4 - RETURN HOSE
Fig. 63 Power Streering Fluid Reservoir Mounting
1 - MOUNTING BOLTS
2 - POWER STEERING FLUID RESERVOIR
PT
PUMP
19 - 63
RESERVOIR (Continued)
INSTALLATION
INSTALLATION - 1.6L ENGINE
(1) Align the guide on the rear of the reservoir
with the mounting bracket and push reservoir down-
ward until reservoir clicks into place in the bracket.
(2) Install the supply hose onto the bottom of the
reservoir (Fig. 61). Slide the hose clamp into position
on the fluid reservoir and attach it. Be sure hose
clamp in installed past bead on fluid reservoir
fitting.
(3) Install the return hose onto the reservoir (Fig.
61). Slide the hose clamp into position on the fluid
reservoir and attach it. Be sure hose clamp in
installed past bead on fluid reservoir fitting.
(4) Fill the fluid reservoir to the proper level.
(Refer to 19 - STEERING/PUMP/FLUID - STAN-
DARD PROCEDURE - POWER STEERING FLUID
LEVEL CHECKING)
(5) Start the engine and let run for a few seconds,
then turn the engine off.
(6) Add fluid as necessary.
(7) Install the filler cap.
INSTALLATION - 2.0L/2.4L ENGINE
(1) Install
the
power
steering
fluid
reservoir
bracket to the engine with mounting bolts (Fig. 63).
Tighten bolts to 10 N·m (90 in.lb.).
NOTE: Make sure the throttle cable is routed in
front of the reservoir just below the upper lip.
(2) Install the fluid supply hose onto the power
steering fluid reservoir fitting (Fig. 62).
(3) Slide the hose clamp on the fluid supply hose
up into position on the fluid reservoir and install it.
Be sure hose clamp in installed past bead on fluid
reservoir fitting.
CAUTION: Make sure the supply hose is routed
above the engine timing chain cover but below
engine wiring harness. The power steering fluid
supply hose must remain clear of any unfriendly
surface that can cause possible damage to it.
(4) Install the fluid return hose onto the power
steering fluid reservoir fitting (Fig. 62).
(5) Slide the hose clamp on the fluid supply hose
up into position on the fluid reservoir and install it.
Be sure hose clamp in installed past bead on fluid
reservoir fitting.
(6) Install plastic engine cover.
(7) Fill the fluid reservoir to the proper level.
(Refer to 19 - STEERING/PUMP/FLUID - STAN-
DARD PROCEDURE - POWER STEERING FLUID
LEVEL CHECKING)
(8) Start the engine and let run for a few seconds,
then turn the engine off.
(9) Add fluid if necessary.
(10) Install the filler cap.
INSTALLATION - 2.2L DIESEL
(1) Attach reservoir to vehicle using 2 mounting
bolts (Fig. 64). Tighten mounting bolts to a torque of
54 N·m (40 ft. lbs.).
(2) Slide supply hose onto reservoir fitting (Fig.
58). Expand hose clamp and slide it over hose on res-
ervoir fitting. Secure clamp once it is past bead
formed into fluid reservoir fitting.
(3) Slide return hose onto reservoir fitting (Fig.
51). Expand hose clamp and slide it over hose on res-
ervoir fitting. Secure clamp once it is past bead
formed into fluid reservoir fitting.
(4) Install
engine
air
cleaner.
(Refer
to
9
-
ENGINE/AIR
INTAKE
SYSTEM/AIR
CLEANER
HOUSING - INSTALLATION)
(5) Install engine top appearance cover (Fig. 57).
(6) Fill fluid reservoir to proper level. (Refer to 19
- STEERING/PUMP/FLUID - STANDARD PROCE-
DURE
-
POWER
STEERING
FLUID
LEVEL
CHECKING)
(7) Start engine and let run for a few seconds,
then turn engine off.
(8) Add fluid if necessary.
(9) Install reservoir filler cap.
Fig. 64 Power Steering Fluid Reservoir Mounting
19 - 64
PUMP
PT
RESERVOIR (Continued)
TRANSAXLE
TABLE OF CONTENTS
page
page
. . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . 95
G288 MANUAL TRANSAXLE
TABLE OF CONTENTS
page
page
G288 MANUAL TRANSAXLE
. . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . 17
. . . . . . . . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION—2.2L TURBO DIESEL
. . . . . . . . . . . . . . . . . . . . . . . 43
. . . . . . . . . . . . . . . . . . . . . . . 44
AXLE SEAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
. . . . . . . . . . . . . . . . . . . . . . . . . 48
BACKUP LAMP SWITCH
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
. . . . . . . . . . . . . . . . . . . . . . . . . 49
CLUTCH BELLHOUSING
. . . . . . . . . . . . . . . . . . . . . . . . . 49
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
DETENT PLUG
. . . . . . . . . . . . . . . . . . . . . . . . . 53
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
. . . . . . . . . . . . . . . . . . . . . . . . . 55
DIFFERENTIAL
. . . . . . . . . . . . . . . . . . . . . . . . . 56
. . . . . . . . . . . . . . . . . . . . . . . . . . . 56
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
. . . . . . . . . . . . . . . . . . . . . . . . . 56
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
. . . . . . . . . . . . . . . . . . . . . . . . . 58
FLUID
STANDARD PROCEDURE - FLUID LEVEL
CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . 58
STANDARD PROCEDURE - FLUID DRAIN
AND FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
GEAR SHIFT BOOT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
. . . . . . . . . . . . . . . . . . . . . . . . . 59
GEAR SHIFT CABLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
. . . . . . . . . . . . . . . . . . . . . . . . . 63
ADJUSTMENT - GEARSHIFT CROSSOVER
CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
GEAR SHIFT KNOB
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
. . . . . . . . . . . . . . . . . . . . . . . . . 67
GEAR SHIFT MECHANISM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
. . . . . . . . . . . . . . . . . . . . . . . . . 67
INPUT SHAFT
. . . . . . . . . . . . . . . . . . . . . . . . . 69
. . . . . . . . . . . . . . . . . . . . . . . . . 70
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
OUTPUT SHAFT
. . . . . . . . . . . . . . . . . . . . . . . . . 78
. . . . . . . . . . . . . . . . . . . . . . . . . 79
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
REVERSE SHAFT
. . . . . . . . . . . . . . . . . . . . . . . . . 86
. . . . . . . . . . . . . . . . . . . . . . . . . 87
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
SYNCHRONIZER
. . . . . . . . . . . . . . . . . . . . . . . . . 91
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
. . . . . . . . . . . . . . . . . . . . . . . . . 92
. . . . . . . . . . . . . . . . . . . . . . . . . . 92
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
. . . . . . . . . . . . . . . . . . . . . . . . . 92
TRANSAXLE HOUSING
. . . . . . . . . . . . . . . . . . . . . . . . . 93
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
PT
TRANSAXLE
21 - 1
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