2006 Chrysler PT Cruiser Lamps/Lighting REMOVAL

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Filed Under (Chrysler) by admin on 01-12-2010

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1. 2. 3. 4. 5. Raise vehicle on a hoist. Remove wheel and tire. Remove splash shield as necessary to access headlamp housing. See Fig. 10. Remove grille. Remove the two fascia bolts from behind the grille. See Fig. 19. 1 – ATTACHING POINTS 2 – FRONT FASCIA 6. Remove fasteners attaching fender to fascia on the side being worked on. 7. Remove the three fasteners holding the lower fascia (3) to the lower radiator crossmember. 8. Make sure there is a slight gap (1) between the fender and fascia. 9. Disconnect wire connectors (2, 5, and 7). 10. Remove four nuts (1, 3, and 6) attaching headlamp housing (4). 1 – MOUNTING HOLES 2 – FRONT SIDE MARKER/PARK/TURN SIGNAL LAMP 3 – MOUNTING HOLES 4 – HEADLAMP HOUSING 5 – LOW BEAM CONNECTOR 6 – MOUNTING HOLE 7 – HIGH BEAM CONNECTOR 11. Once the fascia (3) is loosened on the appropriate side and there is a gap between the fascia and the headlamp unit (1), place a shop towel underneath the headlamp unit (2) on the fascia (3) to protect it from scratches and marring. 12. Tilt the bottom of the headlamp unit (1) forward and then pull straight out of fender/fascia opening, taking care not to damage headlamp unit, fender, or fascia (2).

2001 Chrysler Sebring LX POWER WINDOW MOTOR Removal

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Filed Under (Chrysler) by admin on 01-12-2010

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NOTE: This procedure also covers condition where power window cables become disconnected. Removal Remove window regulator. See WINDOW REGULATOR . Remove 2 screws attaching metal cover to power window motor. Remove drum, guide and cables from power window motor. See Fig. 19 . Installation 1. Connect power window motor connector. Turn ignition on. Pull up on power window switch button until power window motor stops. Turn ignition off. Disconnect power window motor connector. 2. Align drum with power window motor square drive using a 1/2″ ratchet. See Fig. 19 . Hold drum and guide assembly in hand when aligning or cables may pull out of drum. When aligning drum, ensure glass bracket in within specified distance from end of regulator. See Fig. 19 . If cables pull out of drum, go to next step. If cables do not pull out of drum, go to step 6 . 3. Place drum, guide and regulator on bench as shown in step “A”. See Fig. 20 . Place drum with square hole facing upward. Place guide with slits facing upward. Place regulator with glass bracket facing down. Place glass bracket in open position on regulator. 4. Place springs over the cable housings then install cables into guide, making sure lowering (longer) cable is installed first as shown in step “B”. Compress springs and tie in compressed positions using wire as shown in steps “C and “D”. 5. Insert lowering (longer) cable into hole at bottom of drum. Wrap cable around bottom of drum until all slack is gone as shown in step “E”. Insert lifting (shorter) cable into hole at top of drum as shown in step “F”. Raise front drum to vertical position and install lifting cable into upper drum groove as shown in step “G”. 6. Hold wires onto drum. Reconnect drum and guide assembly to power window motor. Install metal cover over guide and attach to motor. To complete installation, reverse removal procedure.

1998 Chrysler Town & Country LX SERPENTINE BELT SLIPS OFF IDLER PULLEY

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Filed Under (Chrysler) by admin on 01-12-2010

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SERPENTINE BELT SLIPS OFF IDLER PULLEY Model(s): 1996-1999 Chrysler (NS) Town & Country 1996-1999 Dodge (NS) Caravan 1996-1999 Plymouth (NS) Voyager 1996-1999 Chrysler (GS) Voyager (International Market) SYMPTOM/CONDITION Loss of power steering assist and occurs when driving through deep snow or standing water. Snow or rain can enter the engine compartment from underneath the vehicle and force the serpentine belt off of the idler pulley. DIAGNOSIS Visually inspect the serpentine belt and idler pulley to determine if mis-alignment exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.) from the inboard edge of the idler pulley (Fig. 1 ) when alignment is correct and this bulletin does not apply. If the belt and pulley appear as in Fig. 2 , perform the REPAIR PROCEDURE . REPAIR PROCEDURE This repair is compatible with DaimlerChrysler’s Mobile Service Program and does not require hoists or other full service facility special equipment. 1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise (Fig. 3 ). 2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount. 3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal fastener. DO NOT remove the large nut in the center of the core of the insulator (Fig. 4 ). 4. Remove the load on the engine mount by carefully supporting the engine with a floor jack. 5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine mount assembly. 6. Remove the idler pulley from the engine mounting bracket. (Fig. 3 ). 7. Remove the engine mounting bracket. 8. Install a new engine mounting bracket. Torque the fasteners to 40-68 N.m (30-50 ft-lbs.). 9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 N.m (30-50 ft-lbs.). 10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new belt if there is any evidence of damage to the original one). 11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly release the belt tensioner. 12. Install the engine mount; torque the assembly in the following order, engine mount to rail fasteners 68 N.m (50 ft-lbs.), vertical fastener 102 N.m (75 ft-lbs.), and horizontal fastener 150 N.m (111 ft-lbs.). 13. Install the purge duty cycle solenoid to the engine mount. 14. Start the vehicle and let it run for one minute then turn the engine off. 15. Verify the serpentine belt is properly aligned (Fig. 1 ).

2004 Chrysler Pacifica DISC BRAKE SHOES Removal (Front)

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Filed Under (Chrysler) by admin on 01-12-2010

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1. Remove master cylinder fluid reservoir cap. 2. Raise and support vehicle. 3. Remove tire and wheel assembly. CAUTION: DO NOT overtighten C-clamp. 4. Place appropriately sized C-clamp over brake caliper, placing screw-drive head against outboard shoe and hook against rear of caliper. Slowly tighten screw-drive retracting caliper pistons into bores and brake outboard brake shoe free from caliper fingers. See Fig. 22 . Remove C-clamp. 5. Once outboard shoe is free from caliper fingers, slide caliper inboard on guides providing clearance between the rotor and inboard brake shoe. 6. Slide an appropriate prying tool through center opening in top of caliper behind brake shoe between 2 caliper pistons. Use care not to come in contact with pistons or dust boots potentially damaging them. Pry against rear of inboard brake shoe braking it free from caliper pistons. 7. Remove the 2 brake caliper guide pin bolts. See Fig. 23 . 8. Remove disc brake caliper from brake adapter and hang out of way using wire or a bungee cord. Use care not to overextend brake hose when doing this. 9. Remove brake shoes from disc brake caliper adapter. See Fig. 27 . 10. Install master cylinder fluid reservoir cap. Installation (Front) 1. Place brake shoes in anti-rattle clips on adapter. See Fig. 27 . Make sure clips are properly installed. See Fig. 26 . 2. Install disc brake caliper over brake shoes on brake caliper adapter. See CALIPER . 3. Align guide pin bolt holes with guide pins and install caliper guide pin bolts. See TORQUE SPECIFICATIONS . 4. Install tire and wheel assembly. See TORQUE SPECIFICATIONS . 5. Lower vehicle. 6. Pump brake pedal several times to seat shoes to caliper and brake rotor. 7. Check and fill brake fluid level as necessary. See CHECKING & FILLING under BRAKE FLUID in SERVICE. 8. Road test vehicle making several stops to wear off any foreign material on brakes and to seat brake shoes.

2003 Chrysler PT Cruiser OIL PUMP REMOVAL

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Filed Under (Chrysler) by admin on 01-12-2010

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1. 2. 3. 4. Disconnect negative cable from battery. Remove timing belt. Remove timing belt rear cover. Remove oil pan. 5. Remove crankshaft sprocket using Special Tools 6793 and C-4685-C2 (Fig. 104). 6. Remove crankshaft key (Fig. 105). 7. Remove oil pick-up tube. 8. Remove oil pump (Fig. 106) and front crankshaft seal. DISASSEMBLY 1. To remove the relief valve, proceed as follows: a. Remove the threaded plug and gasket from the oil pump (Fig. 107). b. Remove spring and relief valve (Fig. 107). 2. Remove oil pump cover fasteners, and lift off cover (Fig. 108). 3. Remove pump rotors (Fig. 108). 4. Wash all parts in a suitable solvent and inspect carefully for damage or wear. CLEANING Clean all parts thoroughly. INSPECTION 1. Inspect the mating surface of the oil pump. Surface should be smooth (Fig. 109). Replace pump cover if scratched or grooved. 2. Lay a straightedge across the pump cover surface (Fig. 110). If a 0.025 mm (0.001 inch) feeler gauge can be inserted between cover and straight edge, cover should be replaced. 3. Measure thickness and diameter of outer rotor. If outer rotor thickness measures 9.40 mm (0.370 inch) or less (Fig. 111), or if the diameter is 79.95 mm (3.148 inch) or less, replace outer rotor. 4. If inner rotor measures 9.40 mm (0.370 inch) or less replace inner rotor (Fig. 112) . ASSEMBLY 1. Assemble pump, using new parts as required. Install the inner rotor with chamfer facing the cast iron oil pump cover. 2. Prime oil pump before installation by filling rotor cavity with engine oil. 3. Install cover and tighten fasteners to 12 Nm (105 inch lbs.) (Fig. 108). CAUTION: Oil pump pressure relief valve must be installed as shown in