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    PT Cruiser 2006-2007

    Removal & Installation

    Print

    Non-Turbo Models



    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Siphon as much fluid as possible from the power steering fluid reservoir.
    4.  
    5. Raise and safely support the vehicle.
    6.  
    7. Remove the right front tire and wheel assembly.
    8.  
    9. Remove the screws fastening the front fascia to the reinforcement as necessary in order to access the drive belt splash shield forward fastener screw.
    10.  
    11. Remove the drive belt splash shield fasteners. Remove the shield.
    12.  
    13. Remove the accessory drive belt from the A/C compressor and power steering pump. Refer to the Cooling section for the procedure.
    14.  
    15. Remove the electrical connectors from the A/C compressor.
    16.  
    17. Remove the 4 bolts fastening the A/C compressor to the engine, then move the compressor toward the center of the vehicle, allowing the compressor to settle in place.
    18.  
    19. Remove the pressure hose from the pump in the following fashion:
      1. Place a crowfoot wrench on a long extension onto the pressure hose tube nut at the pump.
      2.  
      3. Place a shop towel between the crowfoot and the pump pulley to avoid slipping and possibly damaging the pulley.
      4.  
      5. Unthread the tube nut from the pump.
      6.  

    20.  
    21. Lower the vehicle.
    22.  
    23. Remove the grille from the front of the vehicle.
    24.  
    25. Remove the hood-opening weather-strip from across the radiator closure panel.
    26.  
    27. Remove the ambient temperature sensor from the radiator closure panel.
    28.  
    29. Remove the fasteners securing the upper radiator closure panel in place, then remove the panel.
    30.  
    31. Lift the cooling module out of its lower mounts and carefully move it toward the left side of the vehicle. It will move only a limited amount with the hoses still connected. Do not force it.
      NOTE
      For additional room, the right side bolts securing the lower radiator closure panel in front of the cooling module can be removed.

    32.  
    33. Using a bungee cord, tie the cooling module forward. Be sure to attach the cord in a location that will not damage the vehicle. Do not over tighten the bungee cord. It just needs to hold the module forward.
    34.  
    35. Remove the clamp securing the supply hose to the power steering pump supply fitting, then remove the hose from the supply fitting.
    36.  
    37. Remove the 3 bolts securing the pump in place.
    38.  
    39. Remove the 2 bolts securing the stamped steel support bracket to the engine block.
    40.  
    41. Remove the bracket.
    42.  
    43. Ease the cooling module forward, don't force it, and remove the power steering pump and pulley.

      Click image to see an enlarged view

      Fig. Power steering pump removal-non-turbo models

    44.  

    To install:

    Click image to see an enlarged view

    Fig. Power steering pump mounting bolts-non-turbo models

    1. Using a lint free towel, wipe clean the open power steering pressure hose end and the power steering pump port. Replace any used O-rings with new. Lubricate the O-ring with clean power steering fluid.
    2.  
    3. Ease the cooling module forward, don't force it, and install the power steering pump and pulley into its mounting area in the same fashion it was removed.
    4.  
    5. Place the pump in mounting position with the stamped steel support bracket behind it. Install the 3 bolts through the bracket and pump, into the threaded engine cover. Do not tighten the bolts at this time.
    6.  
    7. Install the 2 bolts fastening the bracket to the engine block. Tighten the 2 bolts to a torque of 40 ft. lbs. (54 Nm).
    8.  
    9. Tighten the 3 pump mounting bolts previously installed to a torque of 250 inch lbs. (28 Nm).
    10.  
    11. Push the fluid supply hose onto the pump supply fitting. Expand the hose clamp and slide it over the hose and pump supply fitting. Secure the clamp once it is past the bead formed into the fluid reservoir fitting.
      WARNING
      Make sure the supply hose is routed above the engine timing chain cover. The power steering fluid supply hose must remain clear of any unfriendly surface that can cause possible damage to it.

    12.  
    13. Raise and safely support the vehicle.
    14.  
    15. Thread the fluid pressure hose tube nut into the pump.
    16.  
    17. Using a crowfoot wrench on a long extension with a torque wrench, tighten the pressure hose tube nut at the power steering pump to a torque of 23 ft. lbs. (31 Nm).
    18.  
    19. Install the four bolts fastening the A/C compressor to the engine. Tighten the mounting bolts to a torque of 250 inch lbs. (28 Nm).
    20.  
    21. Install the A/C compressor electrical connectors.
    22.  
    23. Install the A/C drive belt. Refer to the Cooling section for the procedure.
    24.  
    25. Install the drive belt splash shield and fasteners.
    26.  
    27. Install the screws fastening the front fascia to the reinforcement.
    28.  
    29. Install the right front tire and wheel assembly. Install and tighten the wheel mounting nuts to a torque of 100 ft. lbs. (135 Nm).
    30.  
    31. Lower the vehicle.
    32.  
    33. Remove the bungee cord and move the cooling module back into is lower mounts.
    34.  
    35. If previously removed, install the right side bolts securing the lower radiator closure panel in front of the cooling module.
    36.  
    37. Install the radiator closure panel and fasten it in place.
    38.  
    39. Install the ambient temperature sensor on the radiator closure panel.
    40.  
    41. Install the hood-opening weather-strip across the radiator closure panel.
    42.  
    43. Install the grille on the front of the vehicle.
    44.  
    45. Perform the Power Steering Pump Initial Operation service procedure to properly fill and bleed the power steering system.
    46.  
    47. Check for leaks.
    48.  

    Turbocharged Models



    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Siphon as much fluid as possible from power steering fluid reservoir.
    4.  
    5. Raise and safely support the vehicle.
    6.  
    7. Drain engine coolant.
    8.  
    9. Remove right front tire and wheel assembly.
    10.  
    11. Disconnect radiator fan wiring connector.
    12.  
    13. Remove two lower fan mounting screws.
    14.  
    15. Remove accessory drive belt splash shield.
    16.  
    17. Remove accessory drive belt.
    18.  
    19. Carefully lower the vehicle.
    20.  
    21. Remove grille from front of vehicle.
    22.  
    23. Remove hood-opening weather-strip from across radiator closure panel.
    24.  
    25. Remove ambient temperature sensors from radiator closure panel.
    26.  
    27. Remove fasteners securing upper radiator closure panel in place, then remove the panel and lay it out of way.
    28.  
    29. Remove the 2 screws fastening upper radiator hose inlet neck to radiator, then separate inlet neck from radiator.
    30.  
    31. Carefully tip the top of the cooling module toward the front of the vehicle. DO NOT FORCE IT. Using a bungee cord or equivalent, tie the module forward in this position. Be sure to attach the cord in a location that will not damage the vehicle. Do not over tighten the bungee cord. It just needs to hold the module forward.
    32.  
    33. Remove the remaining 4 screws fastening radiator fan to cooling module.
    34.  
    35. Remove the fan.
    36.  
    37. Remove clamp securing fluid return hose to pump reservoir, then remove hose from reservoir fitting. Cap off hose end and reservoir fitting.
    38.  
    39. Back out tube nut securing fluid pressure hose to power steering pump and remove hose from pump. Cap off hose end and pump pressure port.
    40.  
    41. Remove the 3 mounting bolts securing the power steering pump in place.
    42.  
    43. Remove the 2 bolts securing the stamped steel support bracket to engine block. Remove bracket.
    44.  
    45. Remove power steering pump with pulley and reservoir attached.

      Click image to see an enlarged view

      Fig. Power steering pump mounting location-turbo models

    46.  

    To install:

    Click image to see an enlarged view

    Fig. Power steering pump hose connection locations-turbo models

    1. Using a lint free towel, wipe clean open power steering pressure hose end and power steering pump pressure port. Replace any used O-rings with new. Lubricate O-ring with clean power steering fluid.
    2.  
    3. Install power steering pump with pulley and reservoir into its mounting area in same fashion it was removed.
    4.  
    5. Place pump in mounting position with stamped steel support bracket behind it. Install three pump mounting bolts through bracket and pump, into threaded engine cover. DO NOT TIGHTEN BOLTS AT THIS TIME.
    6.  
    7. Install 2 bolts fastening support bracket to engine block. Tighten the 2 bolts to 40 ft. lbs. (54 Nm).
    8.  
    9. Tighten the 3 pump mounting bolts previously installed to 250 inch lbs. (28 Nm).
    10.  
    11. Thread pressure hose tube nut into pump pressure fitting. Tighten tube nut to 23 ft. lbs. (31 Nm).
    12.  
    13. Install the fluid return hose onto power steering fluid reservoir return fitting. Expand hose clamp and slide it over hose and pump return fitting. Secure the clamp once it is past the bead formed into the fluid reservoir fitting.
    14.  
    15. Position the radiator fan and install the 2 upper and the 2 side mounting screws. DO NOT TIGHTEN SCREWS AT THIS TIME. Tighten screws to 55 inch lbs. (6 Nm).
    16.  
    17. Position the cooling module back into its lower mounts.
    18.  
    19. Clean and inspect or replace upper radiator hose inlet neck O-ring, then install inlet neck to radiator. Install 2 mounting screws.
    20.  
    21. Install radiator closure panel and fasten it in place.
    22.  
    23. Install ambient temperature sensors on radiator closure panel.
    24.  
    25. Install hood-opening weather-strip across radiator closure panel.
    26.  
    27. Install grille on front of vehicle.
    28.  
    29. Raise and safely support the vehicle.
    30.  
    31. Install accessory drive belt.
    32.  
    33. Install accessory drive belt splash shield.
    34.  
    35. Install the 2 remaining lower fan mounting screws. Tighten the screws to 55 inch lbs. (6 Nm).
    36.  
    37. Connect the radiator fan wiring connector.
    38.  
    39. Install the right front tire and wheel assembly. Install and tighten the wheel mounting nuts to 100 ft. lbs. (135 Nm).
    40.  
    41. Carefully lower the vehicle.
    42.  
    43. Tighten the 2 upper and the 2 side radiator fan mounting screws to 55 inch lbs. (6 Nm).
    44.  
    45. Fill the cooling system to the proper level.
    46.  
    47. Perform the Power Steering Pump Initial Operation procedure to properly fill and bleed the power steering system.
    48.  
    49. Check for leaks.
    50.  

     
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