PT Cruiser, 2001 - 2005

Starter

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Removal & Installation



2.4L Non-Turbo Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner box cover
     
    Engine structural collar
     
    Starter electrical connectors
     
    Starter

    Click image to see an enlarged view

    Fig. Removal of the starter motor mounting

     

  4.  

To install:

  1. Install the starter and torque the bolts to 40 ft. lbs. (54 Nm). Attach the starter electrical connectors.
  2.  
  3. Install the engine structural collar on models with a automatic transaxle as follows, refer to the illustration for bolt locations:
    1. Place the collar in position and hand tighten the collar to transaxle bolt.
    2.  
    3. Position the power steering hose support bracket and install the collar to oil pan bolt.
    4.  
    5. Place the bending strut in place and hand start the bolt.
    6.  
    7. Install the bolt through the strut and collar and hand tighten.
    8.  
    9. Place the power steering hose support bracket in position and install and hand tighten the remaining bolts.
    10.  
    11. Tighten the collar-to-transmission bolts to 75 ft. lbs. (101 Nm).
    12.  
    13. Install the bolts through the strut and into the block.
    14.  
    15. Tighten the remaining bolts to 45 ft. lbs. (61 Nm).
    16.  

  4.  
  5. Install the engine structural collar on models with a manual transaxle as follows, refer to the illustration for bolt locations:
    1. Place the collar in position and hand tighten the collar to transaxle bolt.
    2.  
    3. Position the power steering hose support bracket and install the collar to oil pan bolt.
    4.  
    5. Position the clutch slave cylinder into position and hand start the bolts.
    6.  
    7. Tighten bolts (1) to 75 ft. lbs. (101 Nm).
    8.  
    9. Tighten bolts (2 and 5) to 45 ft. lbs. (61 Nm).
    10.  
    11. Tighten bolts (3 and 4) to 20 ft. lbs. (28 Nm).

      Click image to see an enlarged view

      Fig. Structural collar assembly-automatic transaxle



      Click image to see an enlarged view

      Fig. Structural collar assembly-manual transaxle

    12.  

  6.  
  7. Install the air cleaner box cover and connect the negative battery cable.
  8.  

2.4L Turbo Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner box cover
     
    Upper starter bolt by pushing the inner cooler up and out of the way
     
    Inner cooler lower hose from the inner cooler
     
    Nuts retaining the inner cooler tube
     
    Studs retaining the power steering lines
     
    Position the power steering lines aside
     
    Engine structural collar
     
    Starter electrical connectors
     
    Starter

    Click image to see an enlarged view

    Fig. Removal of the starter motor mounting

     

  4.  

To install:

  1. Install the starter and torque the bolts to 40 ft. lbs. (54 Nm). Attach the starter electrical connectors.
  2.  
  3. Install the engine structural collar on models with a automatic transaxle as follows, refer to the illustration for bolt locations:
    1. Place the collar in position and hand tighten the collar to transaxle bolt.
    2.  
    3. Position the power steering hose support bracket and install the collar to oil pan bolt.
    4.  
    5. Place the bending strut in place and hand start the bolt.
    6.  
    7. Install the bolt through the strut and collar and hand tighten.
    8.  
    9. Place the power steering hose support bracket in position and install and hand tighten the remaining bolts.
    10.  
    11. Tighten the collar-to-transmission bolts to 75 ft. lbs. (101 Nm).
    12.  
    13. Install the bolts through the strut and into the block.
    14.  
    15. Tighten the remaining bolts to 45 ft. lbs. (61 Nm).
    16.  

  4.  
  5. Install the engine structural collar on models with a manual transaxle as follows, refer to the illustration for bolt locations:
    1. Place the collar in position and hand tighten the collar to transaxle bolt.
    2.  
    3. Position the power steering hose support bracket and install the collar to oil pan bolt.
    4.  
    5. Position the clutch slave cylinder into position and hand start the bolts.
    6.  
    7. Tighten bolts (1) to 75 ft. lbs. (101 Nm).
    8.  
    9. Tighten bolts (2 and 5) to 45 ft. lbs. (61 Nm).
    10.  
    11. Tighten bolts (3 and 4) to 20 ft. lbs. (28 Nm).
    12.  

  6.  
  7. Install or connect the following:

    Power steering lines aside
     
    Studs retaining the power steering lines and tighten to 45 ft. lbs. (61 Nm)
     
    Nuts retaining the inner cooler tube
     
    Inner cooler lower hose to the inner cooler
     
    Upper starter bolt by pushing the inner cooler up and out of the way. Tighten to 40 ft. lbs. (54 Nm).
     
    Air cleaner box cover
     
    Negative battery cable
     

  8.  

 
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