Chrysler PT Cruiser. Manual - part 452

Fig. 4 Power Steering/Air Conditioning Belt

1 - POWER STEERING PUMP PULLEY
2 - POWER STEERING PUMP PULLEY
3 - AIR CONDITIONING COMPRESSOR PULLEY
4 - CRANKSHAFT PULLEY

5 - BELT
6 - IDLER PULLEY
7 - CRANKSHAFT PULLEY
8 - BELT

Fig. 5 Generator Belt

1 - ADJUSTING BOLT
2 - LOCKING NUT
3 - PIVOT BOLT

Fig. 6 Drive Belt Wear Pattern

1 - NORMAL CRACKS - BELT OK
2 - NOT NORMAL CRACKS - REPLACE BELT

7 - 10

ACCESSORY DRIVE - 2.0/2.4L DOHC

DRIVE BELTS (Continued)

INSTALLATION

GENERATOR BELT

NOTE: When installing drive belt onto pulleys, make
sure that belt is properly routed and all V-grooves
make proper contact with pulley grooves.

(1) Install belt and/or adjust belt tension by tight-

ening adjusting bolt. Adjust belt to specification
shown in Belt Tension Chart.

(2) Check belt tension using Special Tool 8371 –

Belt Tension Gauge Adapter, and the DRBIII

t using

the following procedures:

WARNING: DO NOT CHECK BELT TENSION WITH
ENGINE RUNNING.

(a) Connect 8371 to the DRBIII

t following the

instructions provided in tool kit.

(b) Place end of microphone probe approximately

2.54 cm (1 in.) from belt at one of the belt center
span locations shown in (Fig. 7).

your finger or other suitable object)

(d) The frequency of the belt in hertz (Hz) will

display on DRBIII

t screen.

(e) Adjust belt to obtain proper frequency (ten-

sion). Refer to the belt tension chart for specifica-
tions.
(3) Tighten pivot bolt to 54 N·m (40 ft. lbs.) and

locking nut to 54 N·m (40 ft. lbs.) (Fig. 5).

(4) Install power steering pump/air conditioning

compressor drive belt.

BELT TENSION CHART

Accessory

Drive Belt

Belt Tension

Power Steering

Pump and A/C

Compressor

Dynamic Tensioner

Generator

New 135 lb.

235-247 Hz

Used 100 lb.

207-217 Hz

POWER STEERING PUMP/AIR CONDITIONING
COMPRESSOR BELT

NOTE: When installing drive belt onto pulleys, make
sure that belt is properly routed and all V-grooves
make proper contact with pulley grooves.

(1) Install belt (Fig. 4) over all pulleys except for

the power steering pump pulley.

(2) Using a wrench, rotate belt tensioner clockwise

(Fig. 3) until belt can be installed onto power steer-
ing pump pulley. Release spring tension onto belt.

(3) After belt is installed, inspect belt length indi-

cator marks (Fig. 8). The indicator mark should be
within the minimum belt length and maximum belt
length marks. On a new belt, the indicator mark
should align approximately with the nominal belt
length mark.

(4) Install belt splash shield (Fig. 2).

Fig. 7 Belt Center Span

Fig. 8 Belt Length Indicator Marks

1 - BELT LENGTH INDICATOR
2 - MAXIMUM LENGTH
3 - NOMINAL LENGTH
4 - TENSIONER
5 - MINIMUM LENGTH

ACCESSORY DRIVE - 2.0/2.4L DOHC

7 - 11

DRIVE BELTS (Continued)

ADJUSTMENTS

BELT TENSION

For belt tension adjustment procedure, (Refer to 7 -

COOLING/ACCESSORY

DRIVE/DRIVE

BELTS

INSTALLATION).

AUTOMATIC BELT TENSIONER
AND PULLEY

DESCRIPTION

The automatic belt tensioner (Fig. 9) maintains

proper tension on the power steering and air condi-
tioning belt. The tensioner pulley can be serviced
separately.

NOTE: Tensioner arm should move freely and main-
tain 33–46 lb. tension on belt.

REMOVAL

(1) Remove power steering/air conditioning com-

pressor belt (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - REMOVAL).

(2) Remove tensioner mounting bolt and remove

tensioner assembly (Fig. 9).

(3) Remove tensioner pulley, if replacing the pul-

ley.

INSTALLATION

(1) Install tensioner pulley and bolt, if removed.

Tighten bolt to 27 N·m (20 ft. lbs.).

(2) Install

tensioner

assembly

engine

and

tighten bolt to 54 N·m (40 ft. lbs.) (Fig. 9).

(3) Install power steering/air conditioning compres-

sor

belt

(Refer

COOLING/ACCESSORY

DRIVE/DRIVE BELTS - INSTALLATION).

NOTE: Tensioner arm should move freely and main-
tain 33–46 lb. tension on belt.

Fig. 9 Automatic Belt Tensioner

1 - TORQUE STRUT BRACKET
2 - BOLT
3 - AUTOMATIC BELT TENSIONER ASSEMBLY

7 - 12

ACCESSORY DRIVE - 2.0/2.4L DOHC

DRIVE BELTS (Continued)

ENGINE - 1.6L SOHC

TABLE OF CONTENTS

page

ENGINE - 1.6L SOHC

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 14

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 14

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - COOLING

SYSTEM AERATION . . . . . . . . . . . . . . . . . . . 15

DIAGNOSIS AND TESTING - COOLING

SYSTEM DEAERATION . . . . . . . . . . . . . . . . . 15

DIAGNOSIS AND TESTING - COOLING

SYSTEM FLOW CHECK . . . . . . . . . . . . . . . . 15

DIAGNOSIS AND TESTING - COOLING

SYSTEM LEAK TESTING . . . . . . . . . . . . . . . . 15

STANDARD PROCEDURE

STANDARD PROCEDURE - DRAINING

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . 16

STANDARD PROCEDURE - FILLING

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . 16

CLEANING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . 17

COOLANT

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 18

DIAGNOSIS AND TESTING - COOLANT

CONCENTRATION TESTING

. . . . . . . . . . . . . 18

STANDARD PROCEDURE

STANDARD PROCEDURE - COOLANT

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

STANDARD PROCEDURE - ROUTINE

COOLANT LEVEL CHECK . . . . . . . . . . . . . . . 18

STANDARD PROCEDURE - ADDING

ADDITIONAL COOLANT . . . . . . . . . . . . . . . . . 19

HOSE CLAMPS

DESCRIPTION - HOSE CLAMPS

. . . . . . . . . . . 19

COOLANT RECOVERY CONTAINER

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 19

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 19

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 20

ENGINE BLOCK HEATER

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 20

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 20

DIAGNOSIS AND TESTING - ENGINE BLOCK

HEATER TESTING

. . . . . . . . . . . . . . . . . . . . . 20

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 21

ENGINE COOLANT TEMP SENSOR

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 21

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 21

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 21

ENGINE COOLANT THERMOSTAT AND

HOUSING
REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 22

RADIATOR PRESSURE CAP

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 22

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 22

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - COOLING

SYSTEM PRESSURE CAP TESTING . . . . . . . 22

DIAGNOSIS AND TESTING - COOLING

SYSTEM PRESSURE RELIEF TESTING . . . . 23

CLEANING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . 23

RADIATOR DRAINCOCK

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 24

RADIATOR FAN

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 24

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . 24

DIAGNOSIS AND TESTING - RADIATOR FAN

. . 25

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 26

RADIATOR

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

CLEANING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . 28

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 28

HEATER RETURN TUBE

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 28

WATER PUMP/POWER STEERING PUMP

ASSEMBLY
DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . 29

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

DISASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . 30

ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 31

ENGINE - 1.6L SOHC

7 - 13

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