Chrysler PT Cruiser 2001 Service Manual Supplement page 1162

PT
REMOVAL AND INSTALLATION (Continued)
ing column lower coupling up through its hole in the
dash panel.
(6) 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.
(7) 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. 10). 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 (113 ft. lbs.).
(8) Fasten the engine torque strut to the right for-
ward corner of the front suspension crossmember
using its mounting bolt (Fig. 8). Follow the procedure
described in the ENGINE section to properly align
and tighten the torque strut and it's mounting bolts.
(9) Install the washer on the end of the stud
extending from the torque strut bolt (Fig. 8).
(10) Install the pencil strut to the right front cor-
ner of the crossmember and body of the vehicle (Fig.
8). Tighten the pencil strut nuts to a torque of 58
N·m (43 ft. lbs.).
(11) Install the drive-belt splash shield and fasten-
ers (Fig. 9).
(12) Install the screws fastening the front fascia to
the reinforcement (Fig. 9).
(13) Using a lint free towel, wipe clean the open
power steering hose ends and the power steering
gear ports. Replace the pressure hose used O-ring
with new. Lubricate the O-ring with power steering
fluid.
(14) Place the cooler in mounting position and
snap the cooler tube going to the gear into the right
routing clip on the front of the gear. Close the rout-
ing clip.
(15) Install the two screws securing the cooler to
the front suspension crossmember (Fig. 7). Tighten
the screws to a torque of 10 N·m (90 in. lbs.).
(16) Connect the power steering fluid cooler hose
onto the steel gear fitting (Fig. 7). Secure the clamp
on the hose past the bead on the steel fitting.
CAUTION: Forward of the steering gear, the power
steering fluid pressure hose routes between the
front suspension crossmember and the driveshaft.
When tightening the pressure hose tube nut to the
steering gear, the pressure hose must be posi-
tioned (clocked) such that its final routing (after
tightened to 47 N·m (35 ft. lbs.)) offers 4–10 mm
clearance to the front suspension crossmember
(measured at the pressure hose steel-to-rubber cou-
pling).
(17) Attach the power steering fluid pressure hose
to its port on the power steering gear (Fig. 7). While
making sure the hose is not in contact with any vehi-
cle components (see preceding caution), tighten the
pressure hose tube nut at the gear to a torque of 47
N·m (35 ft. lbs.).
(18) Reconnect the wiring harness connector from
the power steering fluid pressure switch (Fig. 6). Be
sure the locking tab on the wiring harness connector
is securely latched.
(19) Perform the following to each outer tie rod:
(a) Place the tie rod heat shield on the knuckle's
steering arm, aligning the hole in the shield with
the hole in the knuckle and the tangs on the out-
side of the shield with the outside configuration of
the steering arm. The shield should now be facing
outboard, away from the power steering gear and
tie rod (Fig. 4).
(b) Attach the outer tie rod end to its steering
knuckle.
(c) Start the attaching nut onto the stud of the
outer tie rod.
(d) While holding the stud of the tie rod station-
ary with a wrench, tighten the attaching nut (Fig.
4).
(e) Using a crowfoot wrench attached to a torque
wrench, tighten the attaching nut to 55 N·m (40 ft.
lbs.).
(20) Install the tire and wheel assemblies back on
vehicle. Tighten the wheel mounting nuts to 135 N·m
(100 ft. lbs.) torque.
(21) Lower the vehicle to ground level.
(22) Install the dash-to-lower coupling seal in
place over the lower coupling's plastic collar.
NOTE: Verify that grease is present on the lip of
the dash-to-coupling seal where it contacts the cou-
pling's plastic collar.
(23) Inside the passenger compartment, reconnect
the steering column lower coupling to the steering
column upper coupling (Fig. 3). Install the coupling
STEERING 19 - 31