2001 PT Cruiser Service Manual

SERVICE MANUAL
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

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
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

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

FASTENER IDENTIFICATION
6 INTRODUCTION PT

FASTENER STRENGTH
PT INTRODUCTION 7

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.)
8 INTRODUCTION PT

METRIC CONVERSION CHART
PT INTRODUCTION 9

LUBRICATION AND MAINTENANCE
TABLE OF CONTENTS
page page
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . . 3
JUMP STARTING, TOWING, AND HOISTING. . . . . 8
LUBRICANTS
TABLE OF CONTENTS
page page
PARTS AND LUBRICANT
RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . 1
CLASSIFICATION OF LUBRICANTS. . . . . . . . . . . . 1
INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . . 2
FLUID CHECK/FILL POINTS AND
LUBRICATION LOCATIONS. . . . . . . . . . . . . . . . . 2
LUBRICATION POINT LOCATIONS . . . . . . . . . . . . 2
SPECIFICATIONS
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . 2
PARTS AND LUBRICANT RECOMMENDATIONS
When service is required, DaimlerChrysler Corpo-
ration recommends that only Mopart brand parts,
lubricants and chemicals be used. Mopar provides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
CLASSIFICATION OF LUBRICANTS
DESCRIPTION
Only lubricants bearing designations defined by
the following organization should be used to service a
DaimlerChrysler Corporation vehicle.
• Society of Automotive Engineers (SAE)
• American Petroleum Institute (API) (Fig. 1)
• National Lubricating Grease Institute (NLGI)
(Fig. 2)
SAE VISCOSITY RATING
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. These are specified with a dual
SAE viscosity grade which indicates the cold-to-hot
temperature viscosity range. Example SAE 5W-30 =
multiple grade engine oil.
DaimlerChrysler Corporation only recommends
multiple grade engine oils.
API QUALITY CLASSIFICATION
This symbol (Fig. 1) on the front of an oil container
means that the oil has been certified by the Ameri-
can Petroleum Institute (API) to meet all the lubri-
cation requirements specified by DaimlerChrysler
Corporation.
Refer to Engine for gasoline engine oil specifica-
tion.
GEAR LUBRICANTS
SAE ratings also apply to multiple grade gear lubri-
cants. In addition, API classification defines the lubri-
cants usage. Such as API GL-5 and SAE 80W-90.
LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 2) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Fig. 1 API Symbol
PT LUBRICATION AND MAINTENANCE 0 - 1

Wheel bearing lubricant is identified by the letter
“G”. Chassis lubricant is identified by the latter “L”.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
INTERNATIONAL SYMBOLS
DESCRIPTION
DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid check and fill locations (Fig. 3).
FLUID CHECK/FILL POINTS AND LUBRICATION
LOCATIONS
The fluid check/fill points and lubrication locations
are located in each applicable area.
LUBRICATION POINT LOCATIONS
Lubrication point locations are located in each
applicable area.
SPECIFICATIONS
FLUID CAPACITIES
Fuel Tank (approximate) . . . . . . . . . 57 L (15.0 gal.)
Engine Oil – With Filter . . . . . . . . . 4.8 L (5.0 qts.)
Cooling System – Includes Heater & Coolant
Recovery Bottle* . . . . . . . . . . . . . . . 7.0 (7.4 qts.)
Automatic Transaxle – Estimated
Service Fill . . . . . . . . . . . . . . . . . . 3.8 L (4.0 qts.)
Automatic Transaxle (41TE) – Overhaul Fill
Capacity with Torque Converter
Empty . . . . . . . . . . . . . . . . . . . . 8.77 L (9.3 qts.)
Manual Transaxle – NV T350 . . . . . . . . 2.4 to 2.7 L
(2.5 to 2.8 qts.)
*Capacities include 1 qt. for coolant reserve tank.
Fig. 2 NLGI Symbol
1 – WHEEL BEARINGS
2 – CHASSIS LUBRICATION
3 – CHASSIS AND WHEEL BEARINGS
Fig. 3 International Symbols
0 - 2 LUBRICATION AND MAINTENANCE PT

MAINTENANCE SCHEDULES
TABLE OF CONTENTS
page page
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . 3
SPECIFICATIONS
UNSCHEDULED INSPECTION. . . . . . . . . . . . . . . . 3
SCHEDULE – A . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SCHEDULE – B . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MAINTENANCE SCHEDULES
There are two maintenance schedules that show
proper service for your vehicle.
First is Schedule – A. It lists all the scheduled
maintenance to be performed under “normal” operat-
ing conditions.
Second is Schedule – B. It is a schedule for vehi-
cles that are operated under the following conditions:
• Frequent short trip driving less than 5 miles
(8 km)
• Frequent driving in dusty conditions
• Extensive idling
• More than 50% of the driving is at sustained
high speeds during hot weather, above 90° F (32° C)
SPECIFICATIONS
UNSCHEDULED INSPECTION
At Each Stop For Fuel
• Check engine oil level and add as required.
• Check windshield washer solvent and add as
required.
Once A Month
• Check tire pressure and look for unusual wear
or damage.
• Inspect the battery and clean and tighten termi-
nals as required.
• Check fluid levels of coolant reservoir, brake
master cylinder, power steering and transmission.
Add fluid as required.
• Check all lights and all other electrical items for
correct operation.
At Each Oil Change
• Inspect the exhaust system.
• Inspect brake hoses.
• Inspect the CV joints and front suspension com-
ponent boots and seals.
• Rotate the tires at each oil change interval
shown on Schedule – A (7,500 miles - 12 000 km) or
every other interval on Schedule – B (6,000 miles -
10 000 km).
• Check the engine coolant level, hoses, and
clamps.
If mileage is less than 7,500 miles (12 000 km)
yearly, replace the engine oil filter at each oil change.
EMISSION CONTROL SYSTEM MAINTENANCE
The scheduled emission maintenance listed in bold
type on the Maintenance Schedules, must be done at
the mileage specified to assure the continued proper
functioning of the emission control system. These,
and all other maintenance services included in this
manual, should be done to provide the best vehicle
performance and reliability. More frequent mainte-
nance may be needed for vehicles in severe operating
conditions such as dusty areas and very short trip
driving.
FLUID FILL POINTS AND LUBRICATION
LOCATIONS
The fluid fill/check locations and lubrication loca-
tions are located in each applicable area.
SCHEDULE – A
7,500 Miles (12 000 km) or at 6 months
• Change the engine oil.
• Replace the engine oil filter.
• Inspect the front brake pads and rear brake lin-
ings.

• Inspect the tie rod ends and boot seals.
• Adjust the generator drive belt tension.
• Replace the engine air cleaner element (fil-
ter).
• Replace the engine spark plugs
ings.
• Check the PCV valve and replace, if neces-
sary. See note #1 at end of schedule.
• Replace the drive belts if necessary.
ter).
• Replace the ignition cables.
• Replace the spark plugs.
ings.
ings.
ter).
• Flush and replace the engine coolant.
• Replace the engine timing belt.
ter).
• Replace the engine spark plugs
#1—This maintenance is recommended by
DaimlerChrysler Corporation to the owner but is not
required to maintain the emissions warranty.
NOTE: Inspection and service should also be per-
formed anytime a malfunction is observed or sus-
pected. Retain all receipts.
SCHEDULE – B
Follow this schedule if you usually operate your
vehicle under one or more of the following conditions.
• Day and night temperatures are below freezing
• Stop and go driving
• Long periods of engine idling
• Driving in dusty conditions
• Short trips of less than 5 miles
• Operation at sustained high speeds during hot
weather, above 90°F (32°C)
• Taxi, police or delivery service
• Trailer towing
At Each Stop For Gasoline
• Check the engine oil level and add as required.
• Check the windshield washer solvent and add as
required.

Once A Month
• Check the tire pressure and look for unusual
wear or damage.
• Inspect the battery and clean and tighten termi-
nals as required.
• Check the fluid levels of coolant reservoir, brake
master cylinder, power steering and transmission.
Add fluid as required.
• Check all lights and all other electrical items for
correct operation.
At Each Oil Change
• Inspect the exhaust system
• Inspect the brake hoses.
• Inspect the CV joints and front suspension com-
ponents.
• Rotate the tires.
• Check the engine coolant level, hoses, and
clamps.
• Check the manual transaxle fluid level.
3,000 Miles (5 000 km)
6,000 Miles (10 000 km)
9,000 Miles (14 000 km)
ings.
12,000 Miles (19 000 km)
ings.
15,000 Miles (24 000 km)
• Inspect the engine air cleaner element (fil-
ter). Replace if necessary. See note #1 at the end of
this schedule.
18,000 Miles (29 000 km)
21,000 Miles (34 000 km)
24,000 Miles (38 000 km)
ings.
27,000 Miles (43 000 km)
30,000 Miles (48 000 km)
• Inspect the PCV valve and replace if necessary.
See note #1 at the end of this schedule.
ter).
• Replace the spark plugs
33,000 Miles (53 000 km)
36,000 Miles (58 000 km)
ings.
39,000 Miles (62 000 km)
42,000 Miles (67 000 km)
45,000 Miles (72 000 km)
ings.
ter). Replace if necessary. See note #1 at the end of
this schedule.
48,000 Miles (77 000 km)
ings.
• Change the automatic transaxle fluid and filter.
• Change brake fluid.

51,000 Miles (82 000 km)
54,000 Miles (86 000 km)
57,000 Miles (91 000 km)
60,000 Miles (96 000 km)
• Inspect the PCV valve and replace if necessary.
See note #1 and #2 at the end of this schedule.
• Inspect the front brake pads and rear brake linings.
• Replace the engine air cleaner element (filter).
• Replace the ignition cables
63,000 Miles (101 000 km)
66,000 Miles (106 000 km)
69,000 Miles (110 000 km)
72,000 Miles (115 000 km)
• Inspect the front brake pads and rear brake linings.
75,000 Miles (120 000 km)
ter) and replace as necessary. See note #1 at the end
of this schedule.
78,000 Miles (125 000 km)
81,000 Miles (130 000 km)
84,000 Miles (134 000 km)
• Inspect front brake pads and rear brake linings
87,000 Miles (139 000 km)
90,000 Miles (144 000 km)
• Check the PCV valve and replace if necessary.
See note #1 and #2 at the end of this schedule.
• Replace the engine air cleaner element (filter).
93,000 Miles (149 000 km)
96,000 Miles (154 000 km)
ings.
• Change the automatic transaxle fluid and filter.
• Change brake fluid.
99,000 Miles (158 000 km)
100,000 Miles (160 000 km)
• Flush and replace the engine coolant.
102,000 Miles (163 000 km)
105,000 Miles (168 000 km)
ter) and replace if necessary. See note #1 at the end
of this schedule.
108,000 Miles (173 000 km)
ings.

111,000 Miles (178 000 km)
114,000 Miles (182 000 km)
117,000 Miles (187 000 km)
120,000 Miles (192 000 km)
• Replace the engine timing belt
ings.
• Check and replace, if necessary, the PCV valve.
See notes # 1 and # 2 at the end of this schedule.
ter).
NOTE: # 1 This maintenance is recommended by
DaimlerChrysler Corporation to the owner but is not
required to maintain the emissions warranty.
NOTE: # 2 This maintenance is not required if the
PCV valve was previously replaced.
NOTE: Operating the vehicle more than 50% in
heavy traffic during hot weather, above 90°F (32°C),
using vehicle for police, taxi, limousine type opera-
tion or trailer towing require the more frequent tran-
saxle service noted in Schedule – B. Perform these
services if vehicle usually operate under these con-
ditions.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.

JUMP STARTING, TOWING, AND HOISTING
TABLE OF CONTENTS
page page
SERVICE PROCEDURES
JUMP STARTING PROCEDURE. . . . . . . . . . . . . . . 8
TOWING RECOMMENDATIONS. . . . . . . . . . . . . . . 9
HOISTING RECOMMENDATIONS . . . . . . . . . . . . 10
SERVICE PROCEDURES
JUMP STARTING PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN BATTERY/STARTING/CHARG-
ING SECTIONS. DO NOT JUMP START A FROZEN
BATTERY, PERSONAL INJURY CAN RESULT. DO
NOT JUMP START WHEN MAINTENANCE FREE
BATTERY INDICATOR DOT IS YELLOW OR BRIGHT
COLOR. DO NOT JUMP START A VEHICLE WHEN
THE BATTERY FLUID IS BELOW THE TOP OF LEAD
PLATES. DO NOT ALLOW JUMPER CABLE
CLAMPS TO TOUCH EACH OTHER WHEN CON-
NECTED TO A BOOSTER SOURCE. DO NOT USE
OPEN FLAME NEAR BATTERY. REMOVE METALLIC
JEWELRY WORN ON HANDS OR WRISTS TO AVOID
INJURY BY ACCIDENTAL ARCING OF BATTERY
CURRENT. WHEN USING A HIGH OUTPUT BOOST-
ING DEVICE, DO NOT ALLOW BATTERY VOLTAGE
TO EXCEED 16 VOLTS. REFER TO INSTRUCTIONS
PROVIDED WITH DEVICE BEING USED.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
• Battery cable clamp condition, clean if necessary.
• Frozen battery.
• Yellow or bright color test indicator, if equipped.
• Low battery fluid level.
• Generator drive belt condition and tension.
• Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 1).
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
Fig. 1 Jumper Cable Clamp Connections
1 – BATTERY POSITIVE CABLE
2 – POSITIVE JUMPER CABLE
3 – TEST INDICATOR
4 – BATTERY NEGATIVE CABLE
5 – BATTERY
6 – NEGATIVE JUMPER CABLE
7 – ENGINE GROUND

CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 minutes), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
• Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
• When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
• Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
TOWING RECOMMENDATIONS
WARNING: DO NOT ALLOW TOWING ATTACHMENT
DEVICES TO CONTACT THE FUEL TANK OR LINES,
FUEL LEAK CAN RESULT. DO NOT LIFT OR TOW
VEHICLE BY FRONT OR REAR BUMPER, OR
BUMPER ENERGY ABSORBER UNITS. DO NOT
VENTURE UNDER A LIFTED VEHICLE IF NOT SUP-
PORTED PROPERLY ON SAFETY STANDS. DO NOT
ALLOW PASSENGERS TO RIDE IN A TOWED VEHI-
CLE. USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-
tem, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle. Do not attach towing device to
front or rear suspension components. Do not
secure vehicle to towing device by the use of front
or rear suspension or steering components.
Remove or secure loose or protruding objects from
a damaged vehicle before towing. Refer to state and
local rules and regulations before towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use of a wheel lift or flat bed towing device (Fig. 2) is
recommended. When using a wheel lift towing device,
be sure the unlifted end of disabled vehicle has at
least 100 mm (4 in.) ground clearance. If minimum
ground clearance cannot be reached, use a towing
dolly. If a flat bed device is used, the approach angle
should not exceed 15 degrees.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums or rotors.
A towed vehicle should be raised until lifted wheels
are a minimum 100 mm (4 in) from the ground. Be
sure there is adequate ground clearance at the oppo-
site end of the vehicle, especially when towing over
rough terrain or steep rises in the road. If necessary,
remove the wheels from the lifted end of the vehicle
and lower the vehicle closer to the ground, to
increase the ground clearance at the opposite end of
the vehicle. Install lug nuts on wheel attaching studs
to retain brake drums or rotors.
LOCKED VEHICLE TOWING
When a locked vehicle must be towed with the
front wheels on the ground, use a towing dolly or flat
bed hauler.
FLAT TOWING WITH TOW BAR
• 4-speed automatic transaxle vehicles can be flat
towed at speeds not to exceed 72 km/h (44 mph) for
not more than 160 km (100 miles). The steering col-
umn must be unlocked and the gear selector must be
in the neutral position.
• 5-speed manual transaxle vehicles can be flat
towed at any legal highway speed for extended dis-
tances. The steering column must be unlocked and
the gear selector must be in the neutral position.
TOWING – FRONT WHEEL LIFT
DaimlerChrysler Corporation recommends that a
vehicle be towed with the front end lifted, whenever
possible.
TOWING – REAR WHEEL LIFT
If a vehicle cannot be towed with the front wheels
lifted, the rear wheels can be lifted provided the fol-
lowing guide lines are observed.
Fig. 2 Recommended Towing Devices
1 – WHEEL LIFT
2 – FLAT BED
SERVICE PROCEDURES (Continued)

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2001 PT Cruiser Service Manual