Assembly; Installation - Chrysler PT Cruiser Service & Repair Manual

2 - 24 FRONT SUSPENSION
STRUT ASSEMBLY (Continued)
• Inspect the upper and lower spring isolators for
material deterioration and distortion.
• Inspect the coil spring for any sign of damage to
the coating.
NOTE: For reassembly, (Refer to 2 - SUSPENSION/
FRONT/STRUT - ASSEMBLY).

ASSEMBLY

NOTE: If the coil spring has been removed from the
spring compressor, proceed with the next step, oth-
erwise, proceed with step Step 3.
(1) Place the coil spring in the compressor follow-
ing the manufacturers instructions. Before compress-
ing the spring, rotate the spring so the end of the top
coil is directly in the front as shown (Fig. 45).
Fig. 45 Upper Coil Spring Positioning
1 - UPPER END OF COIL
2 - COIL SPRING
3 - LOWER END OF COIL
4 - SPRING COMPRESSOR
(2) Slowly compress the coil spring until enough
room is available for strut assembly reassembly.
(3) Install the lower spring isolator on the lower
spring seat of the strut.
(4) Install the strut through the bottom of the coil
spring until the lower spring seat contacts the lower
end of the coil spring. Rotate the strut as necessary
until the clevis bracket is positioned straight outward
away from the compressor (Fig. 41). Install the clamp
on the lower end of the coil spring and strut, so the
strut is held in place.
(5) Install the jounce bumper on the strut shaft.
The jounce bumper is to be installed with the smaller
end pointing downward toward the lower seat (Fig.
44).
(6) Install the dust shield on the strut shaft (Fig.
44). The bottom of the dust shield will snap to the
retainer on top of the strut housing.
(7) If disassembled, reinstall the upper spring iso-
lator on the upper spring seat and bearing.
(8) Install the upper spring seat and bearing on
top of the coil spring. Position the notch formed into
the edge of the upper seat straight out away from the
compressor (Fig. 42). It should line up with the very
end of the coil spring coil.
(9) Install the strut upper mount over the strut
shaft and onto the top of the upper spring seat and
bearing. Position the mount so that the third mount-
ing stud on the mount top is inward toward the com-
pressor, opposite the clevis bracket.
CAUTION: Never use impact or high speed tools to
install the strut shaft nut. Damage to the strut inter-
nal bearings may occur.
(10) Loosely install the retaining nut on the strut
shaft. Install Strut Nut Socket (on the end of a
torque wrench), Special Tool 6864, on the strut shaft
retaining nut (Fig. 43). Next, install a socket on the
hex on the end of the strut shaft. While holding the
strut shaft from turning, tighten the strut shaft
retaining nut to a torque of 75 N·m (55 ft. lbs.).
(11) Slowly release the tension from the coil spring
by backing off the compressor drive completely. As
the tension is relieved, make sure the upper mount
and seat and bearing align properly. Verify the upper
mount does not bind.
(12) Remove the clamp from the lower end of the
coil spring and strut. Push back the spring compres-
sor upper and lower hooks, then remove the strut
assembly from the spring compressor.
(13) Install the strut assembly on the vehicle.
(Refer to 2 - SUSPENSION/FRONT/STRUT

INSTALLATION)

INSTALLATION
(1) Install the strut assembly into the strut tower,
aligning the three studs on the strut upper mount
with the holes in strut tower. Install the three
mounting nuts on the studs (Fig. 40). Tighten the
three nuts to a torque of 34 N·m (25 ft. lbs.).
(2) Close the hood of the vehicle.
PT
-