PT Cruiser, 2001 - 2005

Engine

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Removal & Installation




NOTE
After all components are installed on the engine, a DRB® scam tool is necessary to perform the camshaft and crankshaft timing relearn procedure.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly recover the air conditioning system refrigerant.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Drain the cooling system.
  8.  
  9. Drain the engine oil.
  10.  
  11. Remove or disconnect the following:

    Battery and battery tray
     
    Throttle and cruise control cables
     
    Powertrain Control Module (PCM) wiring harness
     
    Positive cable from the Power Distribution Center (PDC) and ground wire
     
    Ground wire from the body to the engine
     
    Brake booster vacuum hose
     
    Proportional purge hoses from the intake manifold
     
    Coolant recovery hose
     
    Heater hoses
     
    Upper radiator support crossmember
     
    Upper and lower radiator hoses
     
    A/C line from the condenser
     
    A/C lines from the junction at the upper torque strut
     
    Cooler lines, if equipped
     
    Fan cooling module assembly
     
    Transmission shift linkage and electrical connectors
     
    Clutch hydraulic lines, if equipped
     
    Power steering hoses from the radiator on turbo models
     
    Radiator fan, radiator and condenser on 2003-06 models
     
    Both front wheels and the right inner splash shield
     
    Halfshafts
     
    Accessory drive belts
     
    Alternator and support brackets
     
    Charge air cooler hoses on turbo models
     
    Downstream Oxygen Sensor (O 2 S)
     
    Exhaust system from the manifold
     
    Power steering pressure hose on Non-Turbo models
     
    Power steering hoses from the steering gear on turbo models
     
    Lower engine torque strut, if equipped
     
    Upper and lower heat shields, elbow support bracket, turbocharger support bract and elbow if equipped with a turbocharger
     
    Structural collar
     
    Torque converter bolts
     
    A/C compressor
     
    Power steering return line
     
    Power steering pump
     

  12.  
  13. Raise the vehicle enough to allow an engine dolly and cradle to be placed under the engine.
  14.  
  15. Loosen the engine support posts in order to allow movement for positioning onto the engine locating holes and flange on the engine bedplate. Lower the vehicle and position the cradle until the engine is resting on the support posts. Tighten the mounts to the cradle frame. This will keep the support posts from moving when removing or installing the engine and transaxle.
  16.  
  17. Install safety straps around the engine to the cradle; tighten the straps and lock them into position.
  18.  
  19. Raise the vehicle enough to see if the straps are tight enough to hold the cradle assembly to the engine.
  20.  
  21. Lower the vehicle so the weight of the engine and transaxle ONLY is on the cradle.
  22.  
  23. Remove the engine and transaxle mount through-bolts.
  24.  
  25. Raise the vehicle slowly, it might be necessary to move the engine/transaxle assembly with the cradle to allow removal around the body flanges.

    Click image to see an enlarged view

    Fig. Left engine mount location and bolt identification



    Click image to see an enlarged view

    Fig. Exploded view of the right mount through bolt

  26.  

To install:

  1. Install or connect the following:

    Engine/transaxle assembly by lowering the vehicle over the assembly
     
    Engine and transaxle mounts and torque the bolts to 87 ft. lbs. (118 Nm)
     
    Upper torque strut
     

  2.  
  3. Remove the support fixtures.

    Alternator and support brackets
     
    Halfshafts
     

  4.  
  5. Install the structural collar and torque the bolts, in 3 steps, using the following procedure:
    1. Step 1: Collar-to-oil pan bolts to 30 inch lbs. (3 Nm).
    2.  
    3. Step 2: Collar-to-transmission bolts to 80 ft. lbs. (108 Nm).
    4.  
    5. Step 3: Collar-to-oil pan bolts to 40 ft. lbs. (54 Nm).
    6.  

  6.  
  7. Install or connect the following:

    Upper and lower heat shields, elbow support bracket, turbocharger support bract and elbow if equipped with a turbocharger
     
    Lower engine torque strut and torque the through bolts to 87 ft. lbs. (118 Nm)
     
    Exhaust pipe to the manifold
     
    Downstream O 2 S connector
     
    Charge air cooler hoses on turbocharged models
     
    Power steering pressure hose to the steering gear
     
    A/C compressor
     
    Power steering pump
     
    Drive belts
     
    Right inner splash shield and both front wheels
     
    Power steering return hose
     
    Clutch hydraulic line, electrical connectors and shift linkage, if equipped
     
    Shift linkage and cooler lines, if equipped
     
    Fuel lines
     
    Heater hoses
     
    Engine wiring harness and ground strap
     
    Lower and upper radiator hoses
     
    Fan module assembly
     
    Throttle and speed control cables
     
    PDC, positive battery cable and ground strap
     
    PCM
     
    Battery and battery tray
     
    Battery cables
     

  8.  
  9. Perform the camshaft and crankshaft synchronization procedure.
  10.  
  11. Fill the engine with clean oil.
  12.  
  13. Fill the cooling system.
  14.  
  15. Recharge the A/C system.
  16.  
  17. After all components are installed, perform the camshaft and crankshaft timing relearn procedure as follows:
    1. Connect a DRB or equivalent, scan tool to the DLC (located under the instrument panel, near the steering column).
    2.  
    3. Turn the ignition switch ON , and access the -miscellaneous- screen.
    4.  
    5. Select -re-learn cam/crank- option and follow the directions on the scan tool screen.
    6.  

  18.  
  19. Start the vehicle and check for leaks, repair if necessary.
  20.  

 
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