2000-2010 PT Cruiser Service & Repair Manual

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)

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 Helicoilt recommen- 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 controls. 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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2000-2010 PT Cruiser Service & Repair Manual

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