PT Cruiser 2006-2007

Engine

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Removal & Installation




NOTE
After all components are installed on the engine, a DRBIII® scan 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:

    The battery and battery tray
     
    The throttle and cruise control cables
     
    The Powertrain Control Module (PCM) wiring harness
     
    The positive cable from the Power Distribution Center (PDC) and ground wire
     
    The ground wire from the body to the engine
     
    The brake booster vacuum hose
     
    The proportional purge hoses from the intake manifold
     
    The coolant recovery hose
     
    The heater hoses
     
    The upper radiator support crossmember
     
    The upper and lower radiator hoses
     
    The A/C line from the condenser
     
    The A/C lines from the junction at the upper torque strut
     
    The cooler lines, if equipped
     
    The fan cooling module assembly
     
    The transaxle shift linkage and electrical connectors
     
    The clutch hydraulic lines, if equipped
     
    The power steering hoses from the radiator on turbo models
     
    The radiator fan, radiator and condenser on 2003-06 models
     
    Both front wheels and the right inner splash shield
     
    The halfshafts
     
    The accessory drive belts
     
    The alternator and support brackets
     
    The charge air cooler hoses on turbo models
     
    The downstream Oxygen Sensor (O 2 S)
     
    The exhaust system from the manifold
     
    The power steering pressure hose on Non-Turbo models
     
    The power steering hoses from the steering gear on turbo models
     
    The lower engine torque strut, if equipped
     
    The upper and lower heat shields, elbow support bracket, turbocharger support bract and elbow if equipped with a turbocharger
     
    The structural collar
     
    The torque converter bolts
     
    The A/C compressor
     
    The power steering return line
     
    The 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 the engine/transaxle assembly by lowering the vehicle over the assembly.
  2.  
  3. Install the engine and transaxle mounts and torque the bolts to 87 ft. lbs. (118 Nm).
  4.  
  5. Install the upper torque strut.
  6.  
  7. Remove the support fixtures.
  8.  
  9. Install the alternator and support brackets.
  10.  
  11. Install the halfshafts.
  12.  
  13. 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-transaxle bolts to 80 ft. lbs. (108 Nm).
    4.  
    5. Step 3: Collar-to-oil pan bolts to 40 ft. lbs. (54 Nm).
    6.  

  14.  
  15. Install or connect the following:

    The upper and lower heat shields, elbow support bracket, turbocharger support brace and elbow, if equipped with a turbocharger
     
    The lower engine torque strut and torque the through bolts to 87 ft. lbs. (118 Nm)
     
    The exhaust pipe to the manifold
     
    The downstream O 2 S connector
     
    The charge air cooler hoses on turbocharged models
     
    The power steering pressure hose to the steering gear
     
    The A/C compressor
     
    The power steering pump
     
    The drive belts
     
    The right inner splash shield and both front wheels
     
    The power steering return hose
     
    The clutch hydraulic line, electrical connectors and shift linkage, if equipped
     
    The shift linkage and cooler lines, if equipped
     
    The fuel lines
     
    The heater hoses
     
    The engine wiring harness and ground strap
     
    The lower and upper radiator hoses
     
    The fan module assembly
     
    The throttle and speed control cables
     
    The PDC, positive battery cable and ground strap
     
    The PCM
     
    The battery and battery tray
     
    The battery cables
     

  16.  
  17. Perform the camshaft and crankshaft synchronization procedure.
  18.  
  19. Fill the engine with clean oil.
  20.  
  21. Fill the cooling system.
  22.  
  23. Recharge the A/C system.
  24.  
  25. After all components are installed, perform the camshaft and crankshaft timing relearn procedure as follows:
    1. Connect a DRBIII®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.  

  26.  
  27. Start the vehicle and check for leaks, repair if necessary.
  28.  

 
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