Chrysler PT Cruiser 2001 Service Manual Supplement page 1077

13 - 8 FRAME AND BUMPERS
REMOVAL AND INSTALLATION (Continued)
(14) Using an awl, scribe a line marking the loca-
tion of the front suspension crossmember where it is
mounted against the body of the vehicle (Fig. 7).
Fig. 7 Marking Crossmember Location
1 – SCRIBED LINE
2 – AWL
3 – CROSSMEMBER
(15) Position a transmission jack under the center
of the front suspension crossmember and raise it to
support the bottom of the crossmember.
(16) Loosen all six bolts attaching the front sus-
pension crossmember and lower control arms to the
body of the vehicle. Do not completely remove the
two bolts going through the lower control arm rear
isolator bushings. They are designed to disengage
from the body threads yet stay within the lower con-
trol arm rear isolator bushing. Back the two bolts out
just enough to disengage the tapping plates in the
body of the vehicle. Completely remove the other four
bolts.
(17) Lower the front suspension crossmember.
(18) Remove each lower control arm from the
crossmember by removing the pivot bolts.
INSTALLATION
(1) Install the lower control arms on the front sus-
pension crossmember. Install the pivot bolts, but do
not completely tighten them at this time.
(2) Using the transmission jack, raise the front
suspension crossmember and lower control arms
until the crossmember contacts its mounting spot
against the body and frame rails of the vehicle. As
the crossmember is raised, carefully guide the power
steering gear into mounting position.
(3) Start the two crossmember mounting bolts
through the lower control arm rear isolator bushings
into the tapping plates mounted in the body. Next,
install the two front and the two rear mounting bolts
attaching front suspension crossmember to frame
rails of vehicle. Lightly tighten all six mounting bolts
to approximately 2 N·m (20 in. lbs.) to hold the front
suspension crossmember in position at this time.
NOTE: When reinstalling the front suspension
crossmember back in the vehicle, it is very impor-
tant that the crossmember be attached to the body
in exactly the same spot as when it was removed.
Otherwise, the vehicle's wheel alignment settings
(caster and camber) will be lost.
(4) Using a soft face hammer, tap the front suspen-
sion crossmember back-and-forth or side-to-side until
it is aligned with the previously scribed positioning
marks on the body of the vehicle (Fig. 7). Once the
front suspension crossmember is correctly positioned,
tighten the two crossmember mounting bolts through
the lower control arm rear isolator bushings to a
torque of 250 N·m (185 ft. lbs.), then tighten the four
remaining crossmember mounting bolts to a torque of
153 N·m (120 ft. lbs.).
(5) Tighten the lower control arm front pivot bolts
to a torque of 163 N·m (120 ft. lbs.).
(6) Remove the wire or bungee cord suspending
the power steering gear to the underbody.
(7) Attach the steering gear to the front suspen-
sion crossmember (Fig. 4). Install the four power
steering gear mounting bolts. Tighten the mounting
bolts to a torque of 61 N·m (45 ft. lbs.).
(8) Install the two screws securing the cooler to
the front suspension crossmember. They are located
behind the cooler.
(9) Install each ball joint stud into the steering
knuckle aligning the bolt hole in the knuckle boss
with the notch formed in the side of the ball joint
stud.
(10) Install a new ball joint stud pinch bolt and
nut (Fig. 2). Tighten the nut to a torque of 95 N·m
(70 ft. lbs.).
(11) Fasten the engine torque strut to the right
forward corner of the front suspension crossmember
using its mounting bolt (Fig. 5). Follow the procedure
described in the ENGINE service manual area to
properly align and tighten the torque strut and it's
mounting bolts.
(12) Install the washer on the end of the stud
extending from the torque strut bolt (Fig. 5).
(13) Install the pencil strut to the right front cor-
ner of the crossmember and body of the vehicle (Fig.
5). Tighten the pencil strut nuts to a torque of 58
N·m (43 ft. lbs.).
(14) Install the drive-belt splash shield and fasten-
ers (Fig. 6).
(15) Install the screws fastening the front fascia to
the reinforcement (Fig. 6).
PT