Frames & Bumpers Chrysler PT Cruiser I

SPECIFICATIONS - TIGHTENING

REMOVAL

1. Remove grille «(Refer to BODY/EXTERIOR/GRILLE - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior).
2. Remove front fascia «(Refer to FRAME & BUMPERS/BUMPERS/FRONT FASCIA - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/frames-subframes-crossmembers/#frames-bumpers).
3. Remove bolts attaching reinforcement to the rail assembly and Remove reinforcement. (Scheme 1)
4. Remove bumper reinforcement from vehicle.

Scheme 1

INSTALLATION

1. Place bumper reinforcement in position. (Scheme 1)
2. Install bolts attaching reinforcement to rail assembly.
3. Install front fascia «(Refer to FRAME & BUMPERS/BUMPERS/FRONT FASCIA - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/frames-subframes-crossmembers/#frames-bumpers).
4. Install grille «(Refer to BODY/EXTERIOR/GRILLE - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior).

Scheme 2

Scheme 3

1. Remove grille. «(Refer to BODY/EXTERIOR/GRILLE - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior).
2. Remove three screws attaching splash shield to fascia to access fender flange on each side of vehicle.
3. Remove spring nuts fasteners attaching fascia to fender flange. (Scheme 2)
4. Raise and support vehicle. «(Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/hoistjack/#lubrication-maintenance).
5. Remove three screws attaching air dam and lower fascia to the radiator support crossmember. 1 - FRONT BUMPER FASCIA 2 - FRONT BUMPER ENERGY FOAM 3 - RADIATOR AIR DAM
6. Lower vehicle.
7. Remove two fasteners attaching fascia to the fender bracket. (Scheme 3) 1 - ATTACHING POINTS 2 - FRONT FASCIA
8. Remove fascia to access the fog lamp wire connectors and disconnect, if equipped.
9. Remove fascia from vehicle.
10. Move fascia to a bench.
11. Remove the air dam, retaining fasteners, foam, and fog lamps if equipped. «(Refer to BODY/EXTERIOR/GRILLE - LOWER RADIATOR REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior).
12. Remove lower radiator grille, if equipped. (Scheme 4)

Scheme 4

1. Place fascia on a work bench
2. Install lower radiator grille chrome strips, if equipped. Place chrome strip into position, and press on chrome strip until it is locked into position.
3. Install lower radiator grille, if equipped. see scheme 5 «(Refer to BODY/EXTERIOR/GRILLE - LOWER RADIATOR - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior). 1 - FRONT FASCIA 2 - SPRING NUTS (6) 3 - PUSH PIN FASTENER 4 - LOWER RADIATOR GRILLE 5 - CHROME STRIPS
4. Install air dam, retainer fasteners, foam and fog lamps if equipped. see scheme 7
5. Place fascia in position and connect fog lamp wire connectors.
6. Install two fasteners attaching fascia to the fender bracket. see scheme 6 1 - ATTACHING POINTS 2 - FRONT FASCIA
7. Raise and support vehicle. «(Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/hoistjack/#lubrication-maintenance).
8. Install three screws attaching air dam and lower fascia to the radiator support crossmember.
9. Install spring nuts fasteners attaching fascia to fender flange. see scheme 7
10. Install three screws attaching splash shield to fascia on each side of vehicle.
11. Lower vehicle.
12. Install radiator grille. «(Refer to BODY/EXTERIOR/GRILLE - RADIATOR - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior)

1. Open liftgate.
2. Remove the rubber body plugs or mastic tape patches, if equipped.
3. Remove nuts attaching fascia to lower floor closure. (Scheme 5)and (Scheme 6).
4. Raise vehicle on hoist.
5. Disconnect license lamp.
6. Remove splash shield from fascia in the wheel opening area «(Refer to BODY/EXTERIOR/FRONT END SPLASH SHIELDS - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior).
7. Remove screws attaching fascia to lower quarter panels.
8. Remove fascia from vehicle.

Scheme 5

Scheme 6

1. Position fascia on vehicle. (Scheme 5)and (Scheme 6).
2. Position fascia slots to push pins on lower quarter panels
3. Slide fascia forward on push pins
4. Install screws attaching fascia to lower quarter panels.
5. Install splash shield in the wheel opening area «(Refer to BODY/EXTERIOR/FRONT END SPLASH SHIELDS - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior).
6. Connect license lamp.
7. Lower vehicle.
8. Install nuts attaching fascia to lower floor closure.
9. Install the rubber body plugs or install new mastic tape patches, if equipped.
10. Close liftgate.

1. Remove rear fascia «(Refer to FRAME & BUMPERS/BUMPERS/REAR BUMPER - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/frames-subframes-crossmembers/#frames-bumpers).
2. Remove bolts attaching reinforcement to rear closure panel. (Scheme 7)
3. Remove bumper reinforcement from vehicle.

Scheme 7

1. Position bumper reinforcement to vehicle. (Scheme 7)
2. Install bolts attaching reinforcement to rear closure panel.
3. Install rear fascia.

SPECIFICATIONS - FRAME DIMENSIONS

Frame dimensions are listed in metric scale. All dimensions are from center to center of Principal Locating Point (PLP), or from center to center of PLP and fastener location.

VEHICLE PREPARATION

Position the vehicle on a level work surface. Using screw or bottle jacks, adjust the vehicle PLP heights to the specified dimension above a level work surface. Vertical dimensions can be taken from the work surface to the locations indicated were applicable.

FRAME INDEX

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

1. Raise the vehicle. Refer to «HOISTING»(/chrysler/pt-cruiser/i-2000-2010/remont/hoistjack/#lubrication-maintenance) for the correct lifting procedure.
2. Remove both front tire and wheel assemblies from the vehicle.
3. Remove both stabilizer bar links from the vehicle. (Scheme 14) Remove each link by holding the upper retainer/nut with a wrench and turning the link bolt. 1 - STABILIZER BAR CUSHION RETAINERS 2 - CUSHIONS 3 - FRONT STABILIZER BAR 4 - STABILIZER BAR LINKS
4. Remove the stabilizer bar cushion retainer bolts and retainers and remove the stabilizer bar with cushions attached from the vehicle. (Scheme 14)
5. Remove the nut and pinch bolt clamping each ball joint stud to the steering knuckle. (Scheme 15) 1 - NUT 2 - BOLT 3 - BALL JOINT CAUTION: After removing the steering knuckle from the ball joint stud, do not pull outward on the knuckle. Pulling the steering knuckle outward at this point can separate the inner C/V joint on the driveshaft. Refer to «DIFFERENTIAL & DRIVELINE»(/chrysler/pt-cruiser/i-2000-2010/remont/axle-shafts/#differential-driveline) for further information. NOTE: Use caution when separating the ball joint stud from the steering knuckle, so the ball joint seal does not get cut.
6. Separate each ball joint stud from the steering knuckle by prying down on lower control arm and up against the ball joint boss on the steering knuckle. (Scheme 16) 1 - STEERING KNUCKLE 2 - PRY BAR 3 - LOWER CONTROL ARM 4 - BALL JOINT STUD
7. Remove the two screws securing the cooler to the front suspension crossmember. They are located behind the cooler and can be accessed from above. Allow the cooler to hang out of the way.
8. Using wire or a bungee cord, support and tie off the power steering gear to the underbody of the vehicle, so when the crossmember is lowered, the gear does not fall away, being held to the vehicle by only the steering column coupling and the fluid hoses.
9. Loosen and remove the four bolts attaching the power steering gear to the front suspension crossmember. (Scheme 17) Remove the power steering gear from the front suspension crossmember. 1 - OUTER TIE ROD 2 - JAM NUT 3 - STEERING GEAR 4 - FRONT SUSPENSION CROSSMEMBER
10. Remove the pencil strut from the right front corner of the crossmember and body of the vehicle. (Scheme 18) Remove the washer behind the strut from the torque strut bolt. 1 - NUT 2 - PENCIL STRUT 3 - NUT 4 - FLAT WASHER 5 - LOWER TORQUE STRUT
11. Remove the screws fastening the front fascia to the reinforcement as necessary in order to access the drive-belt splash shield forward fastener screw. (Scheme 19) 1 - FASCIA FASTENERS 2 - FASCIA FASTENERS 3 - SPLASH SHIELD FASTENERS
12. Remove the drive-belt splash shield fasteners. (Scheme 19) Remove the shield.
13. Remove the bolt mounting the engine torque strut to the right forward corner of the front suspension crossmember. (Scheme 18) NOTE: Before removing the front suspension crossmember from the vehicle, the location of the crossmember must be scribed on the body of the vehicle. Do this so that the crossmember can be relocated upon reinstallation against the body of vehicle in the same location as before removal. If the front suspension crossmember is not reinstalled in exactly the same location as before removal, the preset front wheel alignment settings (caster and camber) will be lost.
14. Using an awl, scribe a line marking the location of the front suspension crossmember where it is mounted against the body of the vehicle. (Scheme 20) 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 suspension 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 control 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.

Scheme 21

1. Install the lower control arms on the front suspension 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 important 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 suspension crossmember back-and-forth or side-to-side until it is aligned with the previously scribed positioning marks on the body of the vehicle. (Scheme 20) 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 suspension crossmember. (Scheme 17) 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. (Scheme 15) 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. (Scheme 18) Follow the procedure described in «1.6L SOHC»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) or «2.4L DOHC»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) 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. (Scheme 18)
13. Install the pencil strut to the right front corner of the crossmember and body of the vehicle. (Scheme 18) Tighten the pencil strut nuts to a torque of 58 N.m (43 ft. lbs.).
14. Install the drive-belt splash shield and fasteners. (Scheme 19)
15. Install the screws fastening the front fascia to the reinforcement. (Scheme 19) NOTE: Before installing the stabilizer bar, make sure the bar is not upside-down. The stabilizer bar must be installed with the curve on the outboard ends of the bar facing downward to clear the control arms once fully installed. (Scheme 21) 1 - STABILIZER BAR 2 - LINK 3 - DOWNWARD CURVE 4 - CUSHION RETAINER
16. First, place the stabilizer bar in position on the front suspension crossmember. The slits in each cushion must point toward the front of the vehicle and sit directly on top of the raised beads formed into the stamping on the crossmember. Next, install the cushion retainers, matching the raised beads formed into the cushion retainers to the grooves formed into the cushions. Install the cushion retainer bolts, but do not completely tighten them at this time.
17. Install both stabilizer bar links back on vehicle. (Scheme 14) Start each stabilizer bar link bolt with bushing from the bottom, through the stabilizer bar, inner link bushings, lower control arm, and into the upper retainer/nut and bushing. Do not fully tighten the link assemblies at this time.
18. Install the tire and wheel assemblies back on vehicle. Tighten the wheel mounting nuts to 135 N.m (100 ft. lbs.) torque.
19. Lower the vehicle. NOTE: It may be necessary to put the vehicle on a platform hoist or alignment rack to gain access to the stabilizer bar mounting bolts with the vehicle at curb height.
20. Tighten each stabilizer bar link by holding the upper retainer/nut with a wrench and turning the link bolt. Tighten each link bolt to a torque of 28 N.m (250 in. lbs.).
21. Tighten the stabilizer bar cushion retainer bolts to a torque of 28 N.m (250 in. lbs.).
22. Check the front wheel alignment on the vehicle. Refer to «WHEEL ALIGNMENT»(/chrysler/pt-cruiser/i-2000-2010/remont/suspension-front/#suspension-system__wheel-alignment).

1. The front tow eye contains left hand threads, simply unthread the tow eye from the tow eye bracket. (Scheme 22)

Scheme 22

1. Lubricate the threads and install the front tow eye in the front tow eye bracket. Tighten tow eye until firmly seated against bracket. (Scheme 23) No torque specification is required.

Scheme 23

1. Raise the vehicle on hoist. «(Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/hoistjack/#lubrication-maintenance).
2. Remove four bolts attaching rear side rail tow hook to rear frame rail. (Scheme 24)

Scheme 24

1. Place rear side rail tow hook into position on the rear frame rail. (Scheme 24)
2. Install four bolts attaching rear side rail tow hook to rear frame rail. Tighten bolts to 68 N.m (50 ft. lbs.) torque.
3. Lower the vehicle from hoist.

1. Raise the vehicle on hoist. «(Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/hoistjack/#lubrication-maintenance).
2. Remove the four bolts attaching rear side rail shipping tie down bracket. (Scheme 25)

Scheme 25

1. Place rear side rail shipping tie down bracket into position the rear frame rail. (Scheme 25)
2. Install the four bolts attaching rear side rail shipping tie down bracket to rear frame rail. Tighten bolts to 68 N.m (50 ft. lbs.) torque.
3. Lower the vehicle from hoist.

See also:
• (Refer to BODY/EXTERIOR/GRILLE - REMOVAL)
• (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)
• COLUMN
• DIFFERENTIAL & DRIVELINE
• 1.6L SOHC
• 2.4L DOHC
• WHEEL ALIGNMENT
• (Refer to FRAME & BUMPERS/BUMPERS/FRONT FASCIA - REMOVAL)