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1 Page 1 of 11 1Search FRAME CROSS BAR 2001 Chrysler PT Cruiser 2.4L Eng Base CAUTION: DO NOT attempt to modify any suspension or steering components by heating or bending. Removal [ STABILIZER BAR ] 1. Raise and support vehicle. Remove stabilizer bar links from control arm. Remove bolts attaching stabilizer bar brackets to crossmember. Remove stabilizer bar from vehicle. 2. Inspect for broken or distorted clamps and/or retainers. Inspect bushings for wear, deterioration or damage. Replace components as necessary. If inner crossmember bushing replacement is required, remove by opening split in bushing. Removal [ LOWER CONTROL ARM ] 1. Raise and support vehicle. Remove wheel assembly. Remove ball joint-to-steering knuckle pinch bolt. Remove stabilizer bar links from lower control arms. Loosen bolts attaching stabilizer bar retainers to crossmember. Rotate stabilizer bar away from lower control arm. Using a pry bar, separate ball joint from steering knuckle. DO NOT damage ball joint seal during separation of ball joint stud from steering knuckle. 2. Remove lower control arm-to-crossmember front and rear pivot bolts. Remove lower control arm assembly. Inspect lower control arm for distortion, and check bushings for deterioration. Replace as necessary. Removal [ RACK & PINION ASSEMBLY ] WARNING: On models with Supplemental Restraint System (SRS), before any repairs are performed, disconnect and isolate battery ground cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury. 1. Disconnect and isolate negative battery cable. From inside vehicle, disconnect steering coupler between upper and lower steering column. Raise and support vehicle. 2. Remove front wheels. Remove both outer tie rods from steering knuckles using Tie Rod Separator (MB991113). Disconnect wiring harness from power steering switch. 3. Remove power steering hose bracket from crossmember. Remove power steering hoses from steering gear assembly. For reassembly reference, scribe location of front suspension crossmember to body. 4. Place jack under center of crossmember. Loosen 2 bolts attaching front crossmember to frame. Loosen, but DO NOT remove, 2 bolts attaching rear crossmember to frame.

2 Page 2 of 11 CAUTION: DO NOT allow steering column to rotate with steering gear removed. Clockspring damage may occur and become inoperative. NOTE: Anytime steering gear assembly is removed from vehicle, or tie rod ends are loosened, perform front end alignment. 5. While loosening 2 rear crossmember bolts, lower front crossmember enough to allow steering gear to be removed from crossmember. Remove 4 bolts attaching steering assembly to front crossmember. Carefully remove steering gear assembly from crossmember. REMOVAL [ RADIATOR FAN ] NOTE: The fan motor, fan, and the shroud are serviced as an assembly. WARNING: DO NOT OPEN THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR. 1. Disconnect negative cable from battery. 2. Remove battery and battery tray attaching screws. Move tray rearward for radiator fan clearance. 3. Drain cooling system below upper radiator hose level. 4. Remove grill. 5. Remove upper radiator support crossmember. 6. Remove upper radiator hose from radiator. 7. Hoist vehicle. 8. Disconnect radiator fan electrical connector. 9. Remove the two lower and left side radiator fan screws (3). See Fig 1.

3 Page 3 of 11 Fig 1: Locating Radiator Fan Screws Courtesy of CHRYSLER LLC 10. Lower vehicle and remove the remaining attaching screws (2). See Fig 1. CAUTION: Care should be taken not to damage the radiator cooling fins and tubes during fan removal. 11. Remove radiator fan by lifting up from the engine compartment. Installation [ STABILIZER BAR ] 1. Install NEW crossmember bushings on bar with curved surface up, and split toward front of vehicle. Lift bar into crossmember. Install clamps and bolts hand tight. Install stabilizer

4 Page 4 of 11 bar links into control arms. Tighten retaining nut to specification. See TORQUE SPECIFICATIONS. 2. Lower vehicle so suspension is supporting total vehicle weight. With lower control arm raised to design height, tighten bracket bolts to specification. See TORQUE SPECIFICATIONS. Installation [ RACK & PINION ASSEMBLY ] 1. To install, reverse removal procedure. Lightly tap front suspension crossmember until it is aligned with scribe mark. Assistance may be needed in vehicle to guide steering coupler onto steering gear. 2. Install right rear crossmember bolt first. This correctly locates crossmember. Tighten crossmember mounting bolts to specification. See TORQUE SPECIFICATIONS. Tighten left front rack and pinion mounting bolt first to properly align steering gear. Add power steering fluid. DO NOT use automatic transmission fluid. Bleed system. Check for fluid leaks. Check and adjust toe-in. See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT. Installation [ LOWER CONTROL ARM ] 1. Position lower control arm into crossmember. Install rear pivot bolt, and hand tighten. Install front pivot bolt, and tighten to specification. See TORQUE SPECIFICATIONS. Tighten rear pivot to specification. 2. Install ball joint stud into steering knuckle. Install clamp bolt and nut, and tighten to specification. See TORQUE SPECIFICATIONS. Install stabilizer bar links to stabilizer bar. See Fig 2. Rotate stabilizer bar into position, and position stabilizer bar link into control arm. Install bushings and nuts, and hand-tighten.

5 Page 5 of 11 Fig 2: Stabilizer Bar Link & Bushing Assembly Courtesy of CHRYSLER CORP. 3. Lower vehicle until suspension is supporting weight of vehicle. Tighten stabilizer bar links to specification. Tighten stabilizer bar brackets to specification. See TORQUE SPECIFICATIONS. Check and adjust front end alignment as necessary. INSTALLATION [ RADIATOR FAN ] 1. Install the radiator fan into position on the radiator. 2. Install the upper and right side radiator fan retaining screws and tighten to 6 N.m (55 in. lbs.). 3. Raise vehicle and install the remaining fan attaching screws. Tighten to 6 N.m (55 in. lbs.). 4. Connect radiator fan electrical connector. 5. Lower vehicle and install the upper radiator hose to radiator. Align hose and position clamp so it will not interfere with the engine or the hood. 6. Install upper radiator support crossmember and grill.

6 Page 6 of Install battery tray and battery. 8. Connect cables to battery. 9. Fill cooling system. ENGINE TORQUE STRUT ADJUSTMENT NOTE: Whenever a torque strut bolt(s) is loosened, this procedure must be performed. Upper and lower torque struts need to be adjusted together to assure proper engine positioning and engine mount loading. NOTE: To prevent minimal upward lifting of engine, floor jack must be positioned as shown. See Fig Remove pencil strut. See Fig 4. Loosen upper and lower torque strut attaching bolt at suspension crossmember and shock tower bracket. Engine position may now be adjusted by positioning a suitable floor jack on the forward edge of transmission bellhousing. See Fig With engine supported, remove upper and lower torque struts attachment bolt(s) at shock tower bracket and suspension crossmember. See Fig 5. Verify that torque struts are free to move within shock tower bracket and crossmember. Reinstall torque strut bolt(s), but DO NOT tighten. 3. Carefully apply upward force, allowing upper engine to rotate rearward until distance between center of rearmost attaching stud on engine mount bracket (point "A") and center of hole for washer hose clip on shock tower bracket (point "B") is 4.7" (119 mm). See Fig With engine held at proper position, tighten both upper and lower torque strut bolts to specification. See TORQUE SPECIFICATIONS. Install pencil strut, and tighten nuts to specification. Remove floor jack. CAUTION: Engine must be held in position with jack until both upper and lower torque strut bolts are tightened.

7 Page 7 of 11 Fig 3: Positioning Floor Jack Courtesy of CHRYSLER CORP.

8 Page 8 of 11 Fig 4: Removing Pencil Strut Courtesy of CHRYSLER CORP.

9 Page 9 of 11 Fig 5: Removing Upper & Lower Engine Torque Struts Courtesy of CHRYSLER CORP.

10 Page 10 of 11 Fig 6: Measuring Engine Position (Top View) Courtesy of CHRYSLER CORP. NOTE: Before performing wheel alignment, perform preliminary visual and mechanical inspection of wheels, tires and suspension components. See PRE- ALIGNMENT INSTRUCTIONS in WHEEL ALIGNMENT THEORY & OPERATION article in GENERAL INFORMATION. RIDING HEIGHT ADJUSTMENT Before adjusting alignment, check riding height. Measure height from inboard edge of fenderwell directly above center of wheel, unless specified otherwise. Riding height must be checked with vehicle on level floor, correct size tires properly inflated and fuel tank full. Bounce vehicle several times and allow suspension to settle. Visually inspect vehicle for signs of abnormal height from front to rear and side to side. Check passenger and luggage compartments for extra-heavy items, and remove if present. Riding height

11 Page 11 of 11 between left side and right side of vehicle should vary less than 0.79" (2 mm). Information on riding height between front and rear is not available from manufacturer. See RIDING HEIGHT SPECIFICATIONS. If riding height is not within specification, check, repair or replace suspension components. NOTE: Information on vehicles not listed is not available from manufacturer. RIDING HEIGHT SPECIFICATIONS (1) Application Front In. (mm) Rear In. (mm) 2000 Avenger & Sebring Coupe (2) (2) Breeze, Cirrus & Stratus Sedan ( ) ( ) Concorde, LHS & 300M ( ) ( ) Intrepid ( ) ( ) Neon ( ) ( ) Sebring Convertible ( ) ( ) 2001 Concorde, LHS & 300M ( ) ( ) Intrepid ( ) ( ) Neon ( ) ( ) PT Cruiser ( ) ( ) Sebring Convertible Sebring Coupe & Stratus Coupe (2) (2) (2) (2) (1) (2) Sebring Sedan & Stratus Sedan ( ) ( ) Measured from lowest point of center crossmember to ground. Information is not available.

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