PT Cruiser, 2001 - 2005

Hydraulic System

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Hydraulic System Bleeding




NOTE
It is necessary to bleed the clutch hydraulic release system if the system has lost an excessive amount of fluid and has allowed air into the circuit. Air in the system typically results in a spongy pedal feel, and/or improper clutch release. If air cannot be removed from the system using this procedure, it is necessary to replace both the clutch master cylinder and slave cylinder assemblies.

Except Turbocharged Models
  1. From driver's seat, actuate clutch pedal 60-100 times. Verify clutch operation/pedal feel. If pedal still feels spongy, or clutch does not fully disengage, excessive air is still trapped within the system. Perform the following procedure:
  2.  
  3. Verify fluid level in clutch master cylinder reservoir. Top off with DOT 3 brake fluid as necessary.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove clutch slave cylinder assembly from the transaxle case, but do not disconnect from the system. Allow the slave cylinder hang, making it the lowest part of the system.
    CAUTION
    While slave cylinder is detached from the transaxle, DO NOT actuate the clutch master cylinder. Damage to the slave cylinder will result.

  8.  
  9. Depress slave cylinder pushrod until it bottoms and then release. Repeat this at least ten times, forcing trapped air upwards and out of the system.
  10.  
  11. Re-install slave cylinder into position. Torque slave cylinder to case bolt to 168 inch lbs. (19 Nm).
  12.  
  13. Carefully lower the vehicle.
  14.  
  15. Check and adjust clutch master cylinder fluid level. Actuate clutch pedal thirty (30) times. Verify clutch operation/pedal feel. If pedal still feels spongy, or clutch does not fully disengage, air is still trapped within the system. Repeat Step 3 through Step 7 until air is purged. If several attempts at purging air from the system are unsuccessful, replace both the clutch master cylinder and slave cylinder assemblies.
  16.  
  17. Raise and safely support the vehicle.
  18.  
  19. Carefully lower the vehicle.
  20.  
  21. Top off clutch master cylinder fluid level with DOT 3 brake fluid as necessary.
  22.  

Turbocharged Models

NOTE
Due to the angle and design of the turbo hydraulic system components, gravity and pedal bleeding are less effective and less efficient than the reverse fluid injection method (reverse bleeding). Reverse bleeding is recommended for this system, and requires the use of commercially available injection bleeding equipment.

Alternate Procedure (Pedal Bleeding)
  1. Remove reservoir cap and inspect fluid level. Top off with DOT 3 Brake Fluid. Actuate clutch pedal briskly at least 50 times. Verify release system function. Repeat. If release system is still inoperative, continue with procedure.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove clutch bellhousing access cap to expose system bleed screw.
    WARNING
    Use care not to allow fluid to drain into clutch bellhousing. Excessive fluid will be agitated and sprayed around inside the clutch bellhousing by the rotating flywheel, contaminating the flywheel, disc, and pressure plate, resulting in poor clutch engagement.

  6.  
  7. Using suitable socket/wrench, loosen bleed screw. Immediately install rubber hose to bleed screw to prevent fluid from entering clutch bellhousing. Tighten bleed screw gently with suitable wrench.
  8.  
  9. Lower vehicle.
  10.  
  11. Have helper actuate clutch pedal to floor.
  12.  
  13. Place collection container at end of hose to capture expelled fluid.
  14.  
  15. Using suitable wrench, break bleeder screw loose and tighten to 62 inch lbs. (7 Nm). Do not over-tighten.
  16.  
  17. Have helper release pedal, returning it to at-rest position, and then actuate pedal to floor.
  18.  
  19. Break bleeder screw loose and tighten to 62 inch lbs. (7 Nm). Do not over-tighten.
  20.  
  21. Repeat procedure as necessary, keeping master cylinder reservoir full during the process, until air bubbles are no longer visible in collection container.
  22.  
  23. When air bubbles are no longer visible, actuate clutch pedal briskly at least 50 times.
  24.  
  25. Verify release system function and top off fluid as necessary.
  26.  

Recommended Procedure (Reverse Bleeding)
  1. Remove reservoir cap and inspect fluid level. Top off with DOT 3 Brake Fluid. Actuate clutch pedal briskly at least 50 times. Verify release system function. Repeat. If release system is still inoperative, continue with procedure.
  2.  
  3. Remove reservoir from bracket and empty into collection container.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove clutch bellhousing access cap to expose system bleed screw.
    CAUTION
    Use care not to allow fluid to drain into clutch bellhousing. Excessive fluid will be agitated and sprayed around inside the clutch bellhousing by the rotating flywheel, contaminating the flywheel, disc, and pressure plate, resulting in poor clutch engagement.

  8.  
  9. Using suitable socket/wrench, loosen bleed screw.

    Click image to see an enlarged view

    Fig. Location of the bleed screw for the 2.4L engine

  10.  
  11. Quickly attach hand operated bleed apparatus to bleed screw. Use care not to over-fill reservoir and spill fluid into engine compartment.
  12.  
  13. Operate bleed gun sufficiently to expel air upward through circuit and out of master cylinder reservoir. Fill and empty reservoir three times.
  14.  
  15. Remove bleed apparatus and tighten bleed screw to 62 inch lbs. (7 Nm). Do not over-tighten.
  16.  
  17. Carefully lower the vehicle.
  18.  
  19. Top off reservoir with fluid, then return the cap.
  20.  
  21. Verify system operation. Actuate clutch pedal 50 times. If necessary, repeat procedure until road test confirms that shift issues no longer exist.
  22.  

 
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