Chrysler PT Cruiser 2001 Operating manual

SERVICE MANUAL
SUPPLEMENT
2001
PT CRUISER
NO PART OF THIS PUBLICATION MAY BE
REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM OR
BY ANY MEANS, ELECTRONIC, MECHANICAL,
PHOTOCOPYING, RECORDING, OR OTHERWISE,
WITHOUT THE PRIOR WRITTEN PERMISSION
OF DAIMLERCHRYSLER CORPORATION.
DaimlerChrysler Corporation reserves the right to
make changes in design or to make additions to or
improvements in its products without imposing any
obligations upon itself to install them on its products
previously manufactured.
Copyright © DaimlerChrysler Corporation

FOREWORD
This manual is designed as a supplement. It contains both the 2001 PT Cruiser supplement new infor-
mation and the early 2001 PT Cruiser service manual data. The 2001 supplement pages are highlighted with
a blue banner, and the 2001 early service manual data pages are highlighted with a red banner.
The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. Information describing the operation and use of standard and
optional equipment is included in the Owner’s Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain description, operation, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo-
nents. To assist in locating a group title page, use the Group Tab Locator by clicking to the following page. The
first page of the group has a contents section that lists major topics within the group.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide
DaimlerChrysler Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When
replacing fasteners, always use the same type (part number) fastener as removed.
DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis,
repair methods, or vehicle wiring at any time without prior notice or incurring obligation.
2001 Cruiser Supplement
2001 PT CRUISER

Welcome to the
2001 PT Technical Publications
Click on the icon for the desired manual
Service Manual
Gas Powertrain
Body
Chassis
Transmission

GROUP TAB LOCATOR
IN
Introduction
0
Lubrication and Maintenance
2
Suspension
3
Differential and Driveline
5
Brakes
5a
Brakes
6
Clutch
6a
Clutch
7
Cooling System
7a
Cooling System
8A
Battery
8B
Starting Systems
8C
Charging System
8D
Ignition System
8E
Instrument Panel Systems
8Ea
Instrument Panel Systems
8F
Audio System
8Fa
Audio System
8G
Horn System
8H
Vehicle Speed Control System
8J
Turn Signal and Hazard Warning Systems
8Ja
Turn Signal and Hazard Warning Systems
8K
Wiper and Washer Systems
8Ka
Wiper and Washer Systems
8L
Lamps
8La
Lamps
8M
Restraint Systems
8N
Electrically Heated Systems
8O
Power Distribution Systems
8P
Power Lock Systems
8Pa
Power Lock Systems
8Q
Vehicle Theft/Security Systems
8Qa
Vehicle Theft/Security Systems
8R
Power Seat Systems
8S
Power Window Systems
8T
Power Mirror Systems
8Ta
Power Mirror Systems
8U
Chime Warning Systems
8V
Overhead Console Systems
8W
Wiring Diagrams
9
Engine
9a
Engine
11
Exhaust System
13
Frame and Bumpers
13a
Frame and Bumpers
14
Fuel System
19
Steering
19a
Steering
21
Transaxle
22
Tires and Wheels
23
Body
24
Heating and Air Conditioning
24a
Heating and Air Conditioning
25
Emission Control Systems
Service Manual Comment Forms

INTRODUCTION
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
VEHICLE IDENTIFICATION NUMBER ..........1
VEHICLE SAFETY CERTIFICATION LABEL ......2
BODY CODE PLATE .......................2
SERVICE PROCEDURES
THREADED HOLE REPAIR ..................3
SPECIFICATIONS
INTERNATIONAL VEHICLE CONTROL AND
DISPLAY SYMBOLS .....................3
FASTENER IDENTIFICATION.................4
FASTENER USAGE ........................4
METRIC SYSTEM .........................5
DESCRIPTION AND OPERATION
VEHICLE IDENTIFICATION NUMBER
The Vehicle Identification Number (VIN) is located
on the upper left corner of the instrument panel,
near the left A-Pillar. The VIN consists of 17 charac-
ters in a combination of letters and numbers that
provide specific information about the vehicle (Fig.
1). Refer to VIN Code Decoding Chart.
To protect the consumer from theft and possible
fraud the manufacturer is required to include a
Check Digit at the ninth position of the Vehicle Iden-
tification Number. The check digit is used by the
manufacturer and government agencies to verify the
authenticity of the vehicle and official documenta-
tion. The formula to use the check digit is not
released to the general public.
Fig. 1 Vehicle Identification Number Location
1 - Vehicle Identification Number (VIN)
2 - Instrument Panel
PT INTRODUCTION 1

VIN CODE DECODING
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 3 = Built in Mexico by DiamlerChrysler De Mexico
2 Make C = Chrysler
3 Vehicle Type 4 = Multi-purpose Passenger Vehicle Less Side Air Bags
A = Multi-purpose Passenger Vehicle with Side Air Bags
4 Other F = 1815 - 2267 KG (4000 - 5000 lbs.)
5 Line Y = Cruiser (LHD)
Z = Cruiser (RHD)
6 Series 4 = High Line
7 Body Style B = 4 Door Liftgate
8 Engine B = 2.4 L 4 Cyl. 16V
9 = 2.0 L 4 Cyl. 16V
9 Check Digit See explanation in this section.
10 Model Year 1= 2001
11 Assembly Plant T = Toluca
12 Though 17 Vehicle Build Sequence 6 digit number assigned by assembly plant.
VEHICLE SAFETY CERTIFICATION LABEL
A vehicle safety certification label (Fig. 2) is
attached to the rear facing of the driver’s door. This
label indicates date of manufacture (month and
year), Gross Vehicle Weight Rating (GVWR), Gross
Axle Weight Rating (GAWR) front, Gross Axle Weight
Rating (GAWR) rear and the Vehicle Identification
Number (VIN). The Month, Day and Hour of manu-
facture is also included.
All communications or inquiries regarding the
vehicle should include the Month-Day-Hour and
Vehicle Identification Number.
BODY CODE PLATE
LOCATION AND DECODING
The Body Code Plate is located in the engine com-
partment on the cowl panel. 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 3
DIGITS 1, 2, AND 3
Paint procedure
DIGIT 4
Open Space
DIGITS 5 THROUGH 7
Primary paint
See Group 23, Body for color codes.
DIGIT 8 AND 9
Open Space
DIGITS 10 THROUGH 12
Secondary Paint
DIGIT 13 AND 14
Open Space
Fig. 2 Vehicle Safety Certification Label
2 INTRODUCTION PT
DESCRIPTION AND OPERATION (Continued)

DIGITS 15 THROUGH 18
Interior Trim Code
DIGIT 19
Open Space
DIGITS 20, 21, AND 22
Engine Code
•EDZ = 2.4L Four Cylinder DOHC Gasoline
•ECB = 2.0L Four Cylinder SOHC Gasoline
DIGIT 23
Open Space
BODY CODE PLATE LINE 2
DIGITS 1 THROUGH 12
Vehicle Order Number
DIGITS 13, THROUGH 15
Vinyl Roof Code
DIGITS 16 AND 17
Open space
DIGITS 18 AND 19
Vehicle Shell Line
•PT
DIGITS 20
Carline
•C = Chrysler
DIGIT 21
Price Class
•E = Economy
•H = High Line
•L = Low Line
•M = Mid Line
•P = Premium
•S = Special/Sport
•X = Performance Image
DIGITS 22 AND 23
Body Type
•22 = Two Door Sedan
•42 = Four Door Sedan
BODY CODE PLATE LINE 1
DIGITS 1, 2, AND 3
Transaxle Codes
•DGA = 41TE 4-Speed Automatic Transaxle
•DD4 = NV T350 5-Speed Manual Transaxle
•DD5 = NV T350 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 Identification Number (VIN)
paragraph 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.
SERVICE PROCEDURES
THREADED HOLE REPAIR
DESCRIPTION
Most stripped threaded holes can be repaired using
a Helicoil t. Follow the manufacture recommendation
for application and repair procedures.
SPECIFICATIONS
INTERNATIONAL VEHICLE CONTROL AND
DISPLAY SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following
International Control and Display Symbols chart are
used to identify various instrument controls. The
symbols correspond to the controls and displays that
are located on the instrument panel.
PT INTRODUCTION 3
DESCRIPTION AND OPERATION (Continued)

FASTENER IDENTIFICATION
DESCRIPTION
GRADE/CLASS IDENTIFICATION
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.
FASTENER USAGE
DESCRIPTION
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
Fig. 3
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Low Fuel Warning
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
4 INTRODUCTION PT
SPECIFICATIONS (Continued)

Figure art, specifications and tightening torque ref-
erences in this 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 use.
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.
PT INTRODUCTION 5
SPECIFICATIONS (Continued)

FASTENER IDENTIFICATION
6 INTRODUCTION PT
SPECIFICATIONS (Continued)