Chrysler PT Cruiser Service & Repair Manual page 209

PT
CLUTCH (Continued)
1.6/2.0/2.4L MODELS (Except Turbo)
From driver's seat, actuate clutch pedal 60–100
times. Verify clutch operation/pedal feel. If pedal still
feels spongy, or clutch does not fully disengage,
excessive air is still trapped within the system. Per-
form the following procedure:
(1) Verify fluid level in clutch master cylinder res-
ervoir. Top off with DOT 3 brake fluid as necessary.
(2) Raise vehicle on hoist.
(3) Remove clutch slave cylinder assembly from
the transaxle case (Fig. 3) (Fig. 4), but do not dis-
connect from the system. Allow the slave cylinder
hang, making it the lowest part of the system.
CAUTION: While slave cylinder is detached from the
transaxle, DO NOT actuate the clutch master cylin-
der. Damage to the slave cylinder will result.
Fig. 3 Clutch Slave Cylinder at Transaxle- 1.6L
1 - SLAVE CYLINDER
2 - BOLT
(4) Depress slave cylinder pushrod until it bottoms
and then release. Repeat this at least ten (10) times,
forcing trapped air upwards and out of the system.
(5) Re-install slave cylinder into position. 1.6L
equipped models: Torque slave cylinder to case bolt
to 12 N·m (105 in. lbs.). 2.0/2.4L equipped models:
Torque slave cylinder to case bolt to 19 N·m (168 in.
lbs.).
(6) Lower vehicle.
(7) Check and adjust clutch master cylinder fluid
level. Actuate clutch pedal thirty (30) times. Verify
clutch operation/pedal feel. If pedal still feels spongy,
or clutch does not fully disengage, air is still trapped
within the system. Repeat Step 3 - Step 7 until air is
purged. If several attempts at purging air from the
system are unsuccessful, replace both the clutch mas-
ter cylinder and slave cylinder assemblies.
(8) Raise vehicle.
(9) Lower vehicle.
(10) Top off clutch master cylinder fluid level with
DOT 3 brake fluid as necessary.
Models
Fig. 4 Clutch Slave Cylinder at Transaxle- 2.0/2.4L
1 - SLAVE CYLINDER
2 - BRACKET
DIESEL AND TURBO MODELS
NOTE: Due to the angle and design of the Diesel
and Turbo hydraulic system components, gravity
and pedal bleeding are less effective and less effi-
cient than the reverse fluid injection method
(reverse bleeding). Reverse bleeding is recom-
mended for this system, and requires the use of
commercially available injection bleeding equip-
ment.
RECOMMENDED PROCEDURE (REVERSE BLEEDING)
(1) Remove reservoir cap and inspect fluid level.
Top off with DOT 3 Brake Fluid. Actuate clutch pedal
briskly at least 50 times. Verify release system func-
tion. Repeat. If release system is still inoperative,
continue with procedure.
(2) Remove reservoir from bracket and empty into
collection container.
(3) Raise vehicle on hoist.
(4) Remove clutch bellhousing access cap to expose
system bleed screw (Fig. 5).
CAUTION: Use care not to allow fluid to drain into
clutch bellhousing. Excessive fluid will be agitated
and sprayed around inside the clutch bellhousing
by the rotating flywheel, contaminating the flywheel,
disc, and pressure plate, resulting in poor clutch
engagement.
(5) Using suitable socket/wrench, loosen bleed
screw (Fig. 6).
CLUTCH 6 - 7