Chrysler PT Cruiser Operating instructions

GROUP TAB LOCATOR

Introduction

0Lubrication & Maintenance

2Suspension

3Differential & Driveline

5Brakes

6Clutch

7Cooling

8A Audio

8B Chime/Buzzer

8E Electronic Control Modules

8F Engine Systems

8G Heated Systems

8H Horn

8I Ignition Control

8J Instrument Cluster

8L Lamps

8M Message Systems

8N Power Systems

8O Restraints

8P Speed Control

8Q Vehicle Theft Security

8R Wipers/Washers

8W Wiring

9Engine

11 Exhaust System and Turbocharger

13 Frame & Bumpers

14 Fuel System

19 Steering

21 Transaxle

22 Tires/Wheels

23 Body

24 Heating & Air Conditioning

25 Emissions Control

Component and System Index

Service Manual Comment Forms (Rear of Manual)

Service & Repair Manual

Chrysler PT

Cruiser

INTRODUCTION

TABLE OF CONTENTS

page page

BODY CODE PLATE

DESCRIPTION ..........................1

FASTENER IDENTIFICATION

DESCRIPTION ..........................2

FASTENER USAGE

DESCRIPTION

DESCRIPTION - FASTENER USAGE ........5

DESCRIPTION - THREADED HOLE REPAIR . . 5

INTERNATIONAL SYMBOLS

DESCRIPTION ..........................5

METRIC SYSTEM

DESCRIPTION ..........................6

TORQUE REFERENCES

DESCRIPTION ..........................8

VEHICLE IDENTIFICATION NUMBER

DESCRIPTION - VEHICLE IDENTIFICATION

NUMBER .............................9

VEHICLE SAFETY CERTIFICATION LABEL

DESCRIPTION .........................10

E-MARK LABEL

DESCRIPTION .........................10

VECI LABEL

DESCRIPTION .........................10

MANUFACTURER PLATE

DESCRIPTION .........................10

BODY CODE PLATE

DESCRIPTION

The Body Code Plate (Fig. 1) is located in the

engine compartment on the plenum behind the right

side strut tower (Fig. 2). There are seven lines of

information on the body code plate. Lines 4, 5, 6, and

7 are not used to define service information. Informa-

tion reads from left to right, starting with line 3 in

the center of the plate to line 1 at the bottom of the

plate.

BODY CODE PLATE LINE 2

DIGITS 1, 2, AND 3

Paint procedure

DIGIT 4

Open Space

DIGITS 5 THROUGH 7

Primary paint

(Refer to 23 - BODY/PAINT - SPECIFICATIONS)

for Body Color Codes.

DIGIT 8 AND 9

Open Space

DIGITS 10 THROUGH 12

Secondary Paint

DIGIT 13 AND 14

Open Space

DIGITS 15 THROUGH 18

Interior Trim Code

DIGIT 19

Open Space

Fig. 1 BODY CODE PLATE

1 - PRIMARY PAINT

2 - SECONDARY PAINT

3 - VINYL ROOF

4 - VEHICLE ORDER NUMBER

5 - CAR LINE SHELL

6 - PAINT PROCEDURE

7 - ENGINE

8 - TRIM

9 - TRANSMISSION

10 - MARKET

11 - VIN

PT INTRODUCTION 1

DIGITS 20, 21, AND 22

Engine Code

•EJD = 1.6L Four Cylinder 16 Valves SOHC Gas-

oline

•ECC = 2.0L Four Cylinder 16 Valves DOHC

Gasoline

•EDJ = 2.2L Four Cylinder Turbo Diesel Engine

•EDZ = 2.4L Four Cylinder 16 Valves DOHC Gas-

oline

•EDV = 2.4L Four Cylinder 16 Valves DOHC

H.O. Turbo Gasoline

DIGIT 23

Open Space

BODY CODE PLATE LINE 1

DIGITS 1, 2, AND 3

Transaxle Codes

•DGL = 41TE 4-Speed Electronic Automatic

Transaxle

•DD5 = NV T350 5-Speed Manual Transaxle

•DDD = GETRAG 288 5-Speed Manual Transaxle

DIGIT 4

Open Space

DIGIT 5

Market Code

•C = Canada

•B = International

•M = Mexico

•U = United States

DIGIT 6

Open Space

DIGITS 7 THROUGH 23

Vehicle Identification Number

•(Refer to VEHICLE DATA/VEHICLE INFOR-

MATION/VEHICLE IDENTIFICATION NUMBER -

DESCRIPTION) for proper breakdown of VIN code.

IF TWO BODY CODE PLATES ARE REQUIRED

The last code shown on either plate will be fol-

lowed by END. When two plates are required, the

last code space on the first plate will indicate (CTD)

When a second plate is required, the first four

spaces of each line will not be used due to overlap of

the plates.

FASTENER IDENTIFICATION

DESCRIPTION

The SAE bolt strength grades range from grade 2

to grade 8. The higher the grade number, the greater

the bolt strength. Identification is determined by the

line marks on the top of each bolt head. The actual

bolt strength grade corresponds to the number of line

marks plus 2. The most commonly used metric bolt

strength classes are 9.8 and 10.9. The metric

strength class identification number is imprinted on

the head of the bolt. The higher the class number,

the greater the bolt strength. Some metric nuts are

imprinted with a single-digit strength class on the

nut face. Refer to the Fastener Identification and

Fastener Strength Charts (Fig. 3) and (Fig. 4).

Fig. 2 BODY CODE PLATE 2

1 - BODY CODE PLATE

2 - BODY CODE EMBOSS

2 INTRODUCTION PT

BODY CODE PLATE (Continued)

Fig. 3 FASTENER IDENTIFICATION

PT INTRODUCTION 3

FASTENER IDENTIFICATION (Continued)

Fig. 4 FASTENER STRENGTH

4 INTRODUCTION PT

FASTENER IDENTIFICATION (Continued)

FASTENER USAGE

DESCRIPTION

DESCRIPTION - FASTENER USAGE

WARNING: USE OF AN INCORRECT FASTENER

MAY RESULT IN COMPONENT DAMAGE OR PER-

SONAL INJURY.

Fasteners and torque specifications references in

this Service Manual are identified in metric and SAE

format.

During any maintenance or repair procedures, it is

important to salvage all fasteners (nuts, bolts, etc.)

for reassembly. If the fastener is not salvageable, a

fastener of equivalent specification must be used.

DESCRIPTION - THREADED HOLE REPAIR

Most stripped threaded holes can be repaired using

a Helicoilt. Follow the vehicle or Helicoiltrecommen-

dations for application and repair procedures.

INTERNATIONAL SYMBOLS

DESCRIPTION

The graphic symbols illustrated in the following

International Control and Display Symbols Chart

(Fig. 5) are used to identify various instrument con-

trols. The symbols correspond to the controls and dis-

plays that are located on the instrument panel.

Fig. 5 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS

1 High Beam 13 Rear Window Washer

2 Fog Lamps 14 Fuel

3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature

4 Turn Warning 16 Battery Charging Condition

5 Hazard Warning 17 Engine Oil

6 Windshield Washer 18 Seat Belt

7 Windshield Wiper 19 Brake Failure

8 Windshield Wiper and Washer 20 Parking Brake

9 Windscreen Demisting and Defrosting 21 Front Hood

10 Ventilating Fan 22 Rear hood (Decklid)

11 Rear Window Defogger 23 Horn

12 Rear Window Wiper 24 Lighter

PT INTRODUCTION 5

METRIC SYSTEM

DESCRIPTION

The metric system is based on quantities of one,

ten, one hundred, one thousand and one million.

The following chart will assist in converting metric

units to equivalent English and SAE units, or vise

versa.

CONVERSION FORMULAS AND EQUIVALENT VALUES

MULTIPLY BY TO GET MULTIPLY BY TO GET

in-lbs x

0.11298 = Newton Meters

(N·m) N·m x 8.851 = in-lbs

ft-lbs x

1.3558 = Newton Meters

(N·m) N·m x

0.7376 = ft-lbs

Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x

0.2961 = Inches Hg

psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi

Inches x 25.4 = Millimeters (mm) mm x

0.03937 = Inches

Feet x

0.3048 = Meters (M) M x 3.281 = Feet

Yards x

0.9144 = Meters M x

1.0936 = Yards

mph x

1.6093 = Kilometers/Hr.

(Km/h) Km/h x

0.6214 = mph

Feet/Sec x

0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec

mph x

0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph

Kilometers/Hr. (Km/h) x

0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h)

COMMON METRIC EQUIVALENTS

1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters

1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter

1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter

1 Mile = 1.6 Kilometers

Refer to the Metric Conversion Chart to convert

torque values listed in metric Newton- meters (N·m). Also, use the chart to convert between millimeters

(mm) and inches (in.) (Fig. 6).

6 INTRODUCTION PT

Fig. 6 METRIC CONVERSION CHART

PT INTRODUCTION 7

METRIC SYSTEM (Continued)

TORQUE REFERENCES

DESCRIPTION

Individual Torque Charts appear within many or

the Groups. Refer to the Standard Torque Specifica-

tions Chart for torque references not listed in the

individual torque charts (Fig. 7).

Fig. 7 TORQUE SPECIFICATIONS

8 INTRODUCTION PT

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