Chrysler Pt Cruiser Service Manual 2001 2003

Full download: http://manualplace.com/download/chrysler-pt-cruiser-service-manual-2001-2003/

GROUP TAB LOCATOR

Introduction

0 Lubrication & Maintenance

2 Suspension

3 Differential & Driveline

5 Brakes

6 Clutch

7 Cooling

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

9 Engine

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)

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PT INTRODUCTION 1

INTRODUCTION
TABLE OF CONTENTS

page page

BODY CODE PLATE VEHICLE IDENTIFICATION NUMBER

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...1 DESCRIPTION - VEHICLE IDENTIFICATION
FASTENER IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...2 VEHICLE SAFETY CERTIFICATION LABEL
FASTENER USAGE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
DESCRIPTION E-MARK LABEL
DESCRIPTION - FASTENER USAGE . . . . . ...5 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
DESCRIPTION - THREADED HOLE REPAIR ..5 VECI LABEL
INTERNATIONAL SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...5 MANUFACTURER PLATE
METRIC SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...6
TORQUE REFERENCES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...8

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 Fig. 1 BODY CODE PLATE

Open Space 1 - PRIMARY PAINT
2 - SECONDARY PAINT
3 - VINYL ROOF
DIGITS 5 THROUGH 7 4 - VEHICLE ORDER NUMBER
Primary paint 5 - CAR LINE SHELL
6 - PAINT PROCEDURE
(Refer to 23 - BODY/PAINT - SPECIFICATIONS) 7 - ENGINE
for Body Color Codes. 8 - TRIM
9 - TRANSMISSION
DIGIT 8 AND 9 10 - MARKET
11 - VIN
Open Space
DIGITS 15 THROUGH 18
DIGITS 10 THROUGH 12
Interior Trim Code
Secondary Paint
DIGIT 19
DIGIT 13 AND 14
Open Space
Open Space
2 INTRODUCTION PT
BODY CODE PLATE (Continued)
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.

Fig. 2 BODY CODE PLATE 2 IF TWO BODY CODE PLATES ARE REQUIRED
1 - BODY CODE PLATE The last code shown on either plate will be fol-
2 - BODY CODE EMBOSS lowed by END. When two plates are required, the
last code space on the first plate will indicate (CTD)
DIGITS 20, 21, AND 22 When a second plate is required, the first four
Engine Code spaces of each line will not be used due to overlap of
• EJD = 1.6L Four Cylinder 16 Valves SOHC Gas- the plates.
oline
• ECC = 2.0L Four Cylinder 16 Valves DOHC
Gasoline FASTENER IDENTIFICATION
• EDJ = 2.2L Four Cylinder Turbo Diesel Engine
• EDZ = 2.4L Four Cylinder 16 Valves DOHC Gas- DESCRIPTION
oline The SAE bolt strength grades range from grade 2
• EDV = 2.4L Four Cylinder 16 Valves DOHC to grade 8. The higher the grade number, the greater
H.O. Turbo Gasoline the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
DIGIT 23 bolt strength grade corresponds to the number of line
Open Space marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
BODY CODE PLATE LINE 1 strength class identification number is imprinted on
the head of the bolt. The higher the class number,
DIGITS 1, 2, AND 3 the greater the bolt strength. Some metric nuts are
Transaxle Codes imprinted with a single-digit strength class on the
• DGL = 41TE 4-Speed Electronic Automatic nut face. Refer to the Fastener Identification and
Transaxle Fastener Strength Charts (Fig. 3) and (Fig. 4).
• DD5 = NV T350 5-Speed Manual Transaxle
• DDD = GETRAG 288 5-Speed Manual Transaxle

DIGIT 4
Open Space
PT INTRODUCTION 3
FASTENER IDENTIFICATION (Continued)

Fig. 3 FASTENER IDENTIFICATION

4 INTRODUCTION PT
FASTENER IDENTIFICATION (Continued)

Fig. 4 FASTENER STRENGTH

PT INTRODUCTION 5

FASTENER USAGE DESCRIPTION - THREADED HOLE REPAIR

Most stripped threaded holes can be repaired using
a Helicoilt. Follow the vehicle or Helicoilt recommen-
DESCRIPTION dations for application and repair procedures.

DESCRIPTION - FASTENER USAGE

INTERNATIONAL SYMBOLS
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER- DESCRIPTION
SONAL INJURY. The graphic symbols illustrated in the following
International Control and Display Symbols Chart
Fasteners and torque specifications references in (Fig. 5) are used to identify various instrument con-
this Service Manual are identified in metric and SAE trols. The symbols correspond to the controls and dis-
format. plays that are located on the instrument panel.
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.

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
6 INTRODUCTION PT

METRIC SYSTEM The following chart will assist in converting metric

units to equivalent English and SAE units, or vise
versa.
DESCRIPTION
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million.

CONVERSION FORMULAS AND EQUIVALENT VALUES

MULTIPLY BY TO GET MULTIPLY BY TO GET

in-lbs x = Newton Meters N·m x 8.851 = in-lbs
0.11298 (N·m)
ft-lbs x = Newton Meters N·m x = ft-lbs
1.3558 (N·m) 0.7376
Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x = Inches Hg
0.2961
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x = Inches
0.03937
Feet x = Meters (M) M x 3.281 = Feet
0.3048
Yards x = Meters M x = Yards
0.9144 1.0936
mph x = Kilometers/Hr. Km/h x = mph
1.6093 (Km/h) 0.6214
Feet/Sec x = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
0.3048
mph x = Meters/Sec (M/S) M/S x 2.237 = mph
0.4470
Kilometers/Hr. (Km/h) x = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h)
0.27778

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 Also, use the chart to convert between millimeters
torque values listed in metric Newton- meters (N·m). (mm) and inches (in.) (Fig. 6).
PT INTRODUCTION 7
METRIC SYSTEM (Continued)

Fig. 6 METRIC CONVERSION CHART

8 INTRODUCTION PT

TORQUE REFERENCES tions Chart for torque references not listed in the
individual torque charts (Fig. 7).
DESCRIPTION
Individual Torque Charts appear within many or
the Groups. Refer to the Standard Torque Specifica-

Fig. 7 TORQUE SPECIFICATIONS

PT INTRODUCTION 9

VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION - 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.
8). 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 Fig. 8 VEHICLE IDENTIFICATION NUMBER
authenticity of the vehicle and official documenta- LOCATION
tion. The formula to use the check digit is not 1 - Vehicle Identification Number (VIN)
released to the general public. 2 - Instrument Panel

VIN CODE DECODING

POSITION INTERPRETATION CODE = DESCRIPTION

1 Country of Origin 1 = Built in United States by DiamlerChrysler
3 = Built in Mexico by DiamlerChrysler De Mexico
2 Make C = Chrysler
4 = Multi-purpose Passenger Vehicle Less Side Air Bags
3 Vehicle Type
8 = Multi-purpose Passenger Vehicle with Side Air Bags
4 Other F = 1815 - 2267 KG (4000 - 5000 lbs.)
5 Line Y = Cruiser (LHD)
E = Cruiser (LHD)
5 - Export Line
Z = Cruiser (RHD)
4 = High Line
5 = Premium
6 Series
6 = Sport
X = Special
B = 4-Speed Automatic
6 - Export Transmission
N = 5-Speed Manual
7 Body Style 8 = Hatchback
9 = 2.0L 4 Cyl. Gasoline DOHC (MPI)
8 Engine B = 2.4 L 4 Cyl. 16 Valve Gasoline DOHC
G = 2.4 L 4 Cyl. 16 Valve Gasoline DOHC H.O.
F = 1.6L 4 Cyl. 16V Gasoline SOHC
8 - Export Engine 9 = 2.0L 4 Cyl. Gasoline DOHC (MPI)
U = 2.2L 4 Cyl. Turbo Diesel Engine (MPI)
9 Check Digit See explanation in this section.
10 Model Year 3 = 2003
T = Toluca Assembly
11 Assembly Plant
U = Graz Assembly
12 Though 17 Vehicle Build Sequence 6 digit number assigned by assembly plant.
10 INTRODUCTION PT

VEHICLE SAFETY
CERTIFICATION LABEL
DESCRIPTION
A vehicle safety certification label is attached to
the rear shutface of the driver’s door (Fig. 9). 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.
Fig. 10 E-MARK LABEL
1 - COUNTRY CODE
2 - REGULATION NUMBER
3 - APPROVAL NUMBER
4 - AMENDMENT NUMBER

the label in the engine compartment. It cannot be

removed without defacing information and destroying
the label.
The label contains the vehicle’s emission specifica-
tions and vacuum hose routings. All hoses must be
connected and routed according to the label.

MANUFACTURER PLATE
DESCRIPTION
Fig. 9 VEHICLE SAFETY CERTIFICATION LABEL - The Manufacturer Plate (Fig. 11) is located in the
TYPICAL engine compartment on the passenger side rear cor-
ner of the hood. The plate contains five lines of infor-
E-MARK LABEL mation:
1. Vehicle Identification Number (VIN)
DESCRIPTION 2. Gross Vehicle Mass (GVM)
An E-mark Label (Fig. 10) is located on the rear 3. Gross Train Mass (GTM)
shut face of the driver’s door. The label contains the 4. Gross Front Axle Rating (GFAR)
following information: 5. Gross Rear Axle Rating (GRAR)
• Date of Manufacture
• Month-Day-Hour (MDH)
• Vehicle Identification Number (VIN)
• Country Codes
• Regulation Number
• Regulation Amendment Number
• Approval Number

VECI LABEL
Fig. 11 MANUFACTURER PLATE
DESCRIPTION
All models have a Vehicle Emission Control Infor-
mation (VECI) Label. Chrysler permanently attaches
PT LUBRICATION & MAINTENANCE 0-1

LUBRICATION & MAINTENANCE

TABLE OF CONTENTS

page page

INTERNATIONAL SYMBOLS LUBRICATION POINTS

DESCRIPTION . . . . . . . . . . . . . . . . . . . . ......1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FLUID TYPES MAINTENANCE SCHEDULES
DESCRIPTION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DESCRIPTION - ENGINE OIL AND HOISTING
LUBRICANTS . . . . . . . . . . . . . . . . . . . ... . . .1 STANDARD PROCEDURE - HOISTING . . . . . . . 14
DESCRIPTION - ENGINE COOLANT . . ... . . .3 JUMP STARTING
DESCRIPTION - TRANSMISSION FLUID .. . . .3 STANDARD PROCEDURE - JUMP
DESCRIPTION - FUEL REQUIREMENTS .. . . .3 STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FLUID CAPACITIES TOWING
SPECIFICATIONS - FLUID CAPACITIES . ......5 STANDARD PROCEDURE - TOWING . . . . . . . . 15
FLUID FILL/CHECK LOCATIONS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . ......5

INTERNATIONAL SYMBOLS CONTAMINANTS IN USED ENGINE OIL, CAUSED BY

INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
DESCRIPTION
SKIN WITH SOAP AND WATER. DO NOT WASH
DaimlerChrysler Corporation uses international
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
symbols to identify engine compartment lubricant
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
and fluid inspection and fill locations (Fig. 1).
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
When service is required, DaimlerChrysler Corpo-
ration recommends that only Mopart brand parts,
lubricants and chemicals be used. Mopart provides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
Only lubricants bearing designations defined by
the following organization should be used.
• Society of Automotive Engineers (SAE)
• American Petroleum Institute (API)
• National Lubricating Grease Institute (NLGI)
Fig. 1 INTERNATIONAL SYMBOLS
API SERVICE GRADE CERTIFIED
FLUID TYPES Use an engine oil that is API Certified (GF-3).
MOPARt provides engine oils, meeting Material
Standard MS-6395, that meet or exceed this require-
DESCRIPTION ment.

DESCRIPTION - ENGINE OIL AND LUBRICANTS

WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
0-2 LUBRICATION & MAINTENANCE PT
FLUID TYPES (Continued)
SAE VISCOSITY SYNTHETIC ENGINE OILS
An SAE viscosity grade is used to specify the vis- There are a number of engine oils being promoted
cosity of engine oil. Use only engine oils with multi- as either synthetic or semi-synthetic. If you chose to
ple viscosities such as 5W-30 or 10W-30. These are use such a product, use only those oils that meet the
specified with a dual SAE viscosity grade which indi- American Petroleum Institute (API) and SAE viscos-
cates the cold-to-hot temperature viscosity range. ity standard. Follow the service schedule that
Select an engine oil that is best suited to your par- describes your driving type.
ticular temperature range and variation (Fig. 2).
• SAE 5W-30 engine oil is preferred. SAE 5W-30 MATERIALS ADDED TO ENGINE OIL
engine oils improve low temperature starting and The manufacturer does not recommend the addi-
helps vehicle fuel economy. tion of any additive to the specified engine oil.

GEAR LUBRICANTS
SAE ratings also apply to multigrade gear lubri-
cants. In addition, API classification defines the
lubricants usage. Such as API GL-5 and SAE 75W-
90.

LUBRICANTS AND GREASES

Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 4) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter
Fig. 2 TEMPERATURE/ENGINE OIL VISCOSITY “G”. Chassis lubricant is identified by the latter “L”.
The letter following the usage letter indicates the
ENERGY CONSERVING OIL quality of the lubricant. The following symbols indi-
An Energy Conserving type oil is recommended for cate the highest quality.
gasoline engines. The designation of ENERGY CON-
SERVING is located on the label of an engine oil con-
tainer.

CONTAINER IDENTIFICATION
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the front
label of engine oil plastic bottles and the top of
engine oil cans (Fig. 3).
This symbol means that the oil has been certified Fig. 4 NLGI SYMBOL
by the American Petroleum Institute (API). Diamler- 1 - WHEEL BEARINGS
Chrysler only recommends API Certified (GF-3) 2 - CHASSIS LUBRICATION
engine oils that meet the requirements of Material 3 - CHASSIS AND WHEEL BEARINGS
Standard MS-6395. Use Mopar or an equivalent oil
meeting the specification MS-6395. SPECIALIZED LUBRICANTS AND OILS
Some maintenance or repair procedures may
require the use of specialized lubricants or oils. Con-
sult the appropriate sections in this manual for the
correct application of these lubricants.

Fig. 3 API SYMBOL

PT LUBRICATION & MAINTENANCE 0-3
FLUID TYPES (Continued)

DESCRIPTION - ENGINE COOLANT emergency, it should be replaced with the specified

coolant as soon as possible.
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL- DESCRIPTION - TRANSMISSION FLUID
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT- NOTE: Refer to the maintenance schedules in the
ING. IF INHALED, MOVE TO FRESH AIR AREA. Owner’s Manual for the recommended maintenance
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT (fluid/filter change) intervals for this transaxle.
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
NOTE: All transaxles have a common transmission
COMING IN CONTACT WITH ETHYLENE GLYCOL.
and differential sump. Filling the transaxle accom-
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
modates the differential as well.
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR TRANSMISSION FLUID
AREA. DO NOT OPEN A COOLING SYSTEM WHEN Mopart ATF+4 (Automatic Transmission Fluid-
THE ENGINE IS AT OPERATING TEMPERATURE OR Type 9602) is required in the 41TE automatic. Sub-
HOT UNDER PRESSURE, PERSONAL INJURY CAN stitute fluids can induce torque converter clutch
RESULT. AVOID RADIATOR COOLING FAN WHEN shudder.
ENGINE COMPARTMENT RELATED SERVICE IS Mopart ATF+4 (Automatic Transmission Fluid-
PERFORMED, PERSONAL INJURY CAN RESULT. Type 9602) when new is red in color. The ATF is dyed
red so it can be identified from other fluids used in
CAUTION: Use of Propylene Glycol based coolants the vehicle such as engine oil or antifreeze. The red
is not recommended, as they provide less freeze color is not permanent and is not an indicator of fluid
protection and less boiling protection. condition. As the vehicle is driven, the ATF will begin
to look darker in color and may eventually become
The cooling system is designed around the coolant. brown. This is normal. A dark brown/black fluid
The coolant must accept heat from engine metal, in accompanied with a burnt odor and/or deterioration
the cylinder head area near the exhaust valves and in shift quality may indicate fluid deterioration or
engine block. Then coolant carries the heat to the transmission component failure.
radiator where the tube/fin radiator can transfer the G288 and T350 Manual transaxles require the use
heat to the air. of Mopart ATF+4 (Automatic Transmission Fluid)
The use of aluminum cylinder blocks, cylinder
heads, and water pumps requires special corrosion FLUID ADDITIVES
protection. Mopart Antifreeze/Coolant, 5 DaimlerChrysler strongly recommends against the
Year/100,000 Mile Formula (MS-9769), or the equiva- addition of any fluids to the transmission, other than
lent ethylene glycol base coolant with hybrid organic those automatic transmission fluids listed above.
corrosion inhibitors (called HOAT, for Hybrid Organic Exceptions to this policy are the use of special dyes
Additive Technology) is recommended. This coolant to aid in detecting fluid leaks.
offers the best engine cooling without corrosion when Various “special” additives and supplements exist
mixed with 50% Ethylene Glycol and 50% distilled that claim to improve shift feel and/or quality. These
water to obtain a freeze point of -37°C (-35°F). If it additives and others also claim to improve converter
loses color or becomes contaminated, drain, flush, clutch operation and inhibit overheating, oxidation,
and replace with fresh properly mixed coolant solu- varnish, and sludge. These claims have not been sup-
tion. ported to the satisfaction of DaimlerChrysler and
The green coolant MUST NOT BE MIXED with these additives must not be used. The use of trans-
the orange or magenta coolants. When replacing cool- mission “sealers” should also be avoided, since they
ant the complete system flush must be performed may adversely affect the integrity of transmission
before using the replacement coolant. seals.

CAUTION: MoparT Antifreeze/Coolant, 5 DESCRIPTION - FUEL REQUIREMENTS

Year/100,000 Mile Formula (MS-9769) may not be Your engine is designed to meet all emissions reg-
mixed with any other type of antifreeze. Doing so ulations and provide excellent fuel economy and per-
will reduce the corrosion protection and may result formance when using high quality unleaded gasoline
in premature water pump seal failure. If non-HOAT having an octane rating of 87. The use of premium
coolant is introduced into the cooling system in an gasoline is not recommended. The use of premium
0-4 LUBRICATION & MAINTENANCE PT
FLUID TYPES (Continued)
gasoline will provide no benefit over high quality reg- line retailer whether or not his/her gasoline contains
ular gasoline, and in some circumstances may result MMT.
in poorer performance. It is even more important to look for gasoline with-
Light spark knock at low engine speeds is not out MMT in Canada because MMT can be used at
harmful to your engine. However, continued heavy levels higher than allowed in the United States.
spark knock at high speeds can cause damage and MMT is prohibited in Federal and California refor-
immediate service is required. Engine damage result- mulated gasoline.
ing from operation with a heavy spark knock may
not be covered by the new vehicle warranty. SULFUR IN GASOLINE
Poor quality gasoline can cause problems such as If you live in the northeast United States, your
hard starting, stalling and hesitations. If you experi- vehicle may have been designed to meet California
ence these symptoms, try another brand of gasoline low emission standards with Cleaner-Burning Cali-
before considering service for the vehicle. fornia reformulated gasoline with low sulfur. If such
Over 40 auto manufacturers world-wide have fuels are not available in states adopting California
issued and endorsed consistent gasoline specifications emission standards, your vehicles will operate satis-
(the Worldwide Fuel Charter, WWFC) to define fuel factorily on fuels meeting federal specifications, but
properties necessary to deliver enhanced emissions, emission control system performance may be
performance and durability for your vehicle. We rec- adversely affected. Gasoline sold outside of California
ommend the use of gasolines that meet the WWFC is permitted to have higher sulfur levels which may
specifications if they are available. affect the performance of the vehicle’s catalytic con-
verter. This may cause the Malfunction Indicator
REFORMULATED GASOLINE Lamp (MIL), Check Engine or Service Engine Soon
Many areas of the country require the use of light to illuminate. We recommend that you try a dif-
cleaner burning gasoline referred to as “reformulat- ferent brand of unleaded gasoline having lower sulfur
ed” gasoline. Reformulated gasoline contain oxygen- to determine if the problem is fuel related prior to
ates, and are specifically blended to reduce vehicle returning your vehicle to an authorized dealer for
emissions and improve air quality. service.
We strongly support the use of reformulated gaso-
line. Properly blended reformulated gasoline will pro- CAUTION: If the Malfunction Indicator Lamp (MIL),
vide excellent performance and durability for the Check Engine or Service Engine Soon light is flash-
engine and fuel system components. ing, immediate service is required; see on-board
diagnostics system section.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with
oxygenates such as 10% ethanol, MTBE, and ETBE. MATERIALS ADDED TO FUEL
Oxygenates are required in some areas of the country All gasoline sold in the United States and Canada
during the winter months to reduce carbon monoxide are required to contain effective detergent additives.
emissions. Fuels blended with these oxygenates may Use of additional detergents or other additives is not
be used in your vehicle. needed under normal conditions.

CAUTION: DO NOT use gasoline containing METH- FUEL SYSTEM CAUTIONS

ANOL. Gasoline containing methanol may damage
critical fuel system components. CAUTION: Follow these guidelines to maintain your
vehicle’s performance:

MMT IN GASOLINE • The use of leaded gas is prohibited by Federal

MMT is a manganese-containing metallic additive law. Using leaded gasoline can impair engine perfor-
that is blended into some gasoline to increase octane. mance, damage the emission control system, and
Gasoline blended with MMT provide no performance could result in loss of warranty coverage.
advantage beyond gasoline of the same octane num- • An out-of-tune engine, or certain fuel or ignition
ber without MMT. Gasoline blended with MMT malfunctions, can cause the catalytic converter to
reduce spark plug life and reduce emission system overheat. If you notice a pungent burning odor or
performance in some vehicles. We recommend that some light smoke, your engine may be out of tune or
gasoline free of MMT be used in your vehicle. The malfunctioning and may require immediate service.
MMT content of gasoline may not be indicated on the Contact your dealer for service assistance.
gasoline pump; therefore, you should ask your gaso- • When pulling a heavy load or driving a fully
loaded vehicle when the humidity is low and the tem-
PT LUBRICATION & MAINTENANCE 0-5
FLUID TYPES (Continued)
perature is high, use a premium unleaded fuel to FLUID FILL/CHECK
help prevent spark knock. If spark knock persists,
lighten the load, or engine piston damage may result. LOCATIONS
• The use of fuel additives which are now being
sold as octane enhancers is not recommended. Most DESCRIPTION
of these products contain high concentrations of The fluid check/fill point locations are located in
methanol. Fuel system damage or vehicle perfor- each applicable service manual section.
mance problems resulting from the use of such fuels
or additives is not the responsibility of
DaimlerChrysler Corporation and may not be covered LUBRICATION POINTS
under the new vehicle warranty.
DESCRIPTION
NOTE: Intentional tampering with emissions control Lubrication point locations are located in each
systems can result in civil penalties being assessed applicable Sections.
against you.

MAINTENANCE SCHEDULES
FLUID CAPACITIES DESCRIPTION
Maintenance Schedule Information not included in
SPECIFICATIONS - FLUID CAPACITIES this section, is located in the appropriate Owner’s
Manual.
DESCRIPTION SPECIFICATION There are three maintenance schedules that show
required service for your vehicle.
Fuel Tank 57L (15 gal.)
First is Schedule “B”—ALL ENGINES. It is for
Engine Oil* - 1.6L 4.3L (4.5 qts.) vehicles that are operated under the conditions that
Engine Oil* - 2.0L 4.3L (4.5 qts.) are listed below and at the beginning of the schedule.
• Day or night temperatures are below 0° C
Engine Oil* - 2.2L Diesel 7.0L (7.4 qts.)
(32° F).
Engine Oil* - 2.4L 4.8L (5.0 qts.) • Stop and go driving.
Cooling System** - 1.6L, 6.2L (6.5 qts.) • Extensive engine idling.
2.0L, and 2.4L • Driving in dusty conditions.
Cooling System** - 2.2L 9.0L (9.5 qts.) • Short trips of less than 16 km (10 miles).
Diesel • More than 50% of your driving is at sustained
high speeds during hot weather, above 32° C
Automatic Transaxle - 3.8L (4.0 qts.)
(90° F).†
Estimated Service Fill
• Trailer towing.†L
Automatic Transaxle - 8.1L (8.6 qts.) • Taxi, police, or delivery service (commercial ser-
Overhaul Fill Capacity vice).†L
with Torque Converter • Off-road or desert operation.
Empty • If equipped for and operating with E-85
Manual Transaxle - NV (ethanol) fuel.
2.4 - 2.7L (2.5 - 2.8 qts.)
T350
NOTE: Most vehicles are operated under the condi-
2.2L Turbo Diesel: 2.0L tions listed for Schedule (B(.
Manual Transaxle - (2.1 qts.)
Getrag 288 2.4L Turbo: 1.8L (1.9 Second is Schedule “A”—NON TURBO
qts.) CHARGED ENGINES. It is for vehicles that are not
*(includes new filter) operated under any of the conditions listed under
Schedule 9B9—ALL ENGINES.
**(Includes heater and coolant recovery bottle filled to Second is Schedule “A”—TURBO CHARGED
MAX level.) ENGINES. It is for vehicles that are not operated
under any of the conditions listed under Schedule
9B9—ALL ENGINES.
Use the schedule that best describes your driving
conditions. Where time and mileage are listed, follow
the interval that occurs first.
0-6 LUBRICATION & MAINTENANCE PT
MAINTENANCE SCHEDULES (Continued)
CAUTION: Failure to perform the required mainte- • Check the coolant level, hoses, and clamps.
nance items may result in damage to the vehicle. • Rotate the tires at each oil change interval
shown on Schedule “A”—NON TURBO CHARGED
ENGINES 10 000 km (6,000 miles), Schedule “A”—
At Each Stop for Fuel TURBO CHARGED ENGINES 8 000 km (5,000
• Check the engine oil level about 5 minutes after miles), or every other interval shown on Schedule
a fully warmed engine is shut off. Checking the oil “B”—ALL ENGINES 10 000 km (6,000 miles).
level while the vehicle is on level ground will
improve the accuracy of the oil level reading. Add oil SCHEDULE “B”—ALL ENGINES
only when the level is at or below the ADD or MIN Follow schedule “B”—All Engines if you usually
mark. operate your vehicle under one or more of the follow-
• Check the windshield washer solvent and add if ing conditions. Change the automatic transmission
required. fluid and filter every 77 000 km (48,000 miles) if the
vehicle is usually operated under one or more of the
Once a Month conditions marked with an L.
• Check tire pressure and look for unusual wear Change the manual transaxle fluid every 77 000
or damage. km (48,000 miles) if the vehicle is usually operated
• Inspect the battery and clean and tighten the under one or more of the conditions marked with an
terminals as required. †.
• Check the fluid levels of coolant reservoir, brake • Day or night temperatures are below 0° C
master cylinder, power steering and transaxle and (32° F).
add as needed. • Stop and go driving.
• Check all lights and all other electrical items for • Extensive engine idling.
correct operation. • Driving in dusty conditions.
• Check rubber seals on each side of the radiator • Short trips of less than 16.2 km (10 miles).
for proper fit. • More than 50% of your driving is at sustained
high speeds during hot weather, above 32° C
At Each Oil Change (90° F).†
• Change the engine oil filter. • Trailer towing.†L
• Inspect the exhaust system. • Taxi, police, or delivery service (commercial ser-
• Inspect the brake hoses. vice).†L
• Inspect the CV joints and front suspension com- • Off-road or desert operation.
ponents. • If equipped for and operating with E-85
• Check the automatic transaxle fluid level. (ethanol) fuel.
• Check the manual transaxle fluid level and fill
plug condition.

Miles 3,000 6,000 9,000 12,000 15,000 18,000

(Kilometers) (5 000) (10 000) (14 000) (19 000) (24 000) (29 000)
Change engine oil and X X X X X X
engine oil filter.
Inspect the brake linings. X
Inspect the engine air X
cleaner filter.Replace as
necessary.*
Inspect the PCV make-up air X
filter. Replace as necessary.
Inspect the generator belt, X
and replace as necessary.
Inspect and adjust the power X
steering pump belt tension.
PT LUBRICATION & MAINTENANCE 0-7
MAINTENANCE SCHEDULES (Continued)

Miles 21,000 24,000 27,000 30,000 33,000 36,000

(Kilometers) (34 000) (38 000) (43 000) (48 000) (53 000) (58 000)
Change engine oil and engine X X X X X X
oil filter.
Inspect the brake linings. X X
Replace the engine air X
cleaner filter.
Replace the spark plugs. X
Inspect the tie rod ends and X
boot seals.
Inspect the PCV valve and X
replace as necessary.*
Replace the PCV make-up X
air filter.
Inspect and adjust the power X
steering pump belt tension.
Inspect the generator belt, X
and replace as necessary.

Miles 39,000 42,000 45,000 48,000 51,000 54,000

(Kilometers) (62 000) (67 000) (72 000) (77 000) (82 000) (86 000)
Change engine oil and X X X X X X
engine oil filter.
Inspect the brake linings. X
Change the brake fluid. If X
vehicle is used for trailer
towing.
Inspect the engine air X
cleaner filter. Replace as
necessary.*
Change the automatic X
transaxle fluid and filter.
Change the manual transaxle X
fluid.
Inspect the PCV make-up air X
filter. Replace as necessary.
Inspect and adjust the power X
steering pump belt tension.
Inspect the generator belt, X
and replace as necessary.
Chrysler Pt Cruiser Service Manual 2001 2003
Full download: http://manualplace.com/download/chrysler-pt-cruiser-service-manual-2001-2003/
0-8 LUBRICATION & MAINTENANCE PT
MAINTENANCE SCHEDULES (Continued)

Miles 57,000 60,000 63,000 66,000 69,000 72,000

(Kilometers) (91 000) (96 000) (101 000) (106 000) (110 000) (115 000)
Change engine oil and engine X X X X X X
oil filter.
Inspect the brake linings. X X
Replace the engine air X
cleaner filter.
Replace the spark plugs and X
ignition cables.
Inspect the tie rod ends and X
boot seals.
Inspect the PCV valve and X
replace if necessary. Not
required if previously
changed. * ‡
Inspect the PCV make-up air X
filter. Replace as necessary.
Inspect and adjust the power X
steering pump belt tension.
Inspect the generator belt, X
and replace as necessary.

Miles 75,000 78,000 81,000 84,000 87,000 90,000

(Kilometers) (120 000) (125 000) (130 000) (134 000) (139 000) (144 000)
Change engine oil and engine X X X X X X
oil filter.
Inspect the brake linings. X
Inspect the engine air
cleaner filter and replace as X
necessary.*
Replace the engine air X
cleaner filter.
Replace the spark plugs. X
Inspect the tie rod ends and X
boot seals.
Inspect the PCV valve and
replace if necessary. Not
X
required if previously
changed. * ‡
Replace the engine timing X
belt.*
Inspect the PCV make-up air X
X
filter. Replace as necessary.
Inspect and adjust the power X
X
steering pump belt tension.
Inspect the generator belt, X
X
and replace as necessary.

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