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