Chrysler PT Cruiser 2001 Service Manual Supplement

page of 2930

/ 2930
Contents
Table of Contents
Bookmarks

Table of Contents

Quick Links

SERVICE MANUAL

SUPPLEMENT

2001

PT CRUISER

NO PART OF THIS PUBLICATION MAY BE

REPRODUCED,

STORED

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.

Table of Contents

Chapters

Table of Contents

Summary of Contents for Chrysler PT Cruiser 2001

Page 1 SERVICE MANUAL SUPPLEMENT 2001 PT CRUISER NO PART OF THIS PUBLICATION MAY BE REPRODUCED, STORED 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...
Page 2 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.
Page 3 Welcome to the 2001 PT Technical Publications Click on the icon for the desired manual Service Manual Gas Powertrain Body Chassis Transmission...
Page 4 GROUP TAB LOCATOR Introduction Power Distribution Systems Lubrication and Maintenance Power Lock Systems Suspension Power Lock Systems Differential and Driveline Vehicle Theft/Security Systems Brakes Vehicle Theft/Security Systems Brakes Power Seat Systems Clutch Power Window Systems Clutch Power Mirror Systems Cooling System Power Mirror Systems Cooling System Chime Warning Systems...
Page 5 INTRODUCTION INTRODUCTION TABLE OF CONTENTS page page DESCRIPTION AND OPERATION SPECIFICATIONS VEHICLE IDENTIFICATION NUMBER ..1 INTERNATIONAL VEHICLE CONTROL AND VEHICLE SAFETY CERTIFICATION LABEL ..2 DISPLAY SYMBOLS .
Page 6: Vehicle Identification Number
CODE = DESCRIPTION Country of Origin 3 = Built in Mexico by DiamlerChrysler De Mexico Make C = Chrysler 4 = Multi-purpose Passenger Vehicle Less Side Air Bags Vehicle Type A = Multi-purpose Passenger Vehicle with Side Air Bags Other F = 1815 - 2267 KG (4000 - 5000 lbs.)
Page 7: Body Code Plate
Vehicle Shell Line SERVICE PROCEDURES • PT THREADED HOLE REPAIR DIGITS 20 Carline • C = Chrysler DESCRIPTION Most stripped threaded holes can be repaired using DIGIT 21 a Helicoil . Follow the manufacture recommendation Price Class for application and repair procedures.
Page 8: Display Symbols
INTRODUCTION SPECIFICATIONS (Continued) INTERNATIONAL CONTROL AND DISPLAY SYMBOLS Fig. 3 High Beam Rear Window Washer Fog Lamps Low Fuel Warning Headlamp, Parking Lamps, Panel Lamps Engine Coolant Temperature Turn Warning Battery Charging Condition Hazard Warning Engine Oil Windshield Washer Seat Belt Windshield Wiper Brake Failure Windshield Wiper and Washer...
Page 9 INTRODUCTION SPECIFICATIONS (Continued) Figure art, specifications and tightening torque ref- The following chart will assist in converting metric erences in this manual are identified in metric and units to equivalent English and SAE units, or vise SAE format. versa. During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly.
Page 10: Fastener Identification
INTRODUCTION SPECIFICATIONS (Continued) FASTENER IDENTIFICATION...
Page 11 INTRODUCTION SPECIFICATIONS (Continued) FASTENER STRENGTH...
Page 12 INTRODUCTION SPECIFICATIONS (Continued) CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY TO GET MULTIPLY 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 x 3.377 = Kilopascals (kPa) x 0.2961...
Page 13 INTRODUCTION SPECIFICATIONS (Continued) METRIC CONVERSION CHART...
Page 15 LUBRICATION AND MAINTENANCE 0 - 1 LUBRICATION AND MAINTENANCE TABLE OF CONTENTS page page LUBRICANTS ......1 JUMP STARTING, TOWING, AND HOISTING.
Page 16: International Symbols
0 - 2 LUBRICATION AND MAINTENANCE DESCRIPTION AND OPERATION (Continued) 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.
Page 17: Maintenance Schedules
LUBRICATION AND MAINTENANCE 0 - 3 MAINTENANCE SCHEDULES TABLE OF CONTENTS page page DESCRIPTION AND OPERATION SCHEDULE – A ......3 MAINTENANCE SCHEDULES .
Page 18 0 - 4 LUBRICATION AND MAINTENANCE SPECIFICATIONS (Continued) • Adjust the generator drive belt tension. 30,000 Miles (48 000 km) or at 24 months • Replace the engine air cleaner element (fil- • Change the engine oil. • Replace the engine oil filter. ter).
Page 19 LUBRICATION AND MAINTENANCE 0 - 5 SPECIFICATIONS (Continued) Once A Month 24,000 Miles (38 000 km) • Check the tire pressure and look for unusual • Change the engine oil. • Replace the engine oil filter. wear or damage. • Inspect the battery and clean and tighten termi- •...
Page 20 0 - 6 LUBRICATION AND MAINTENANCE SPECIFICATIONS (Continued) 51,000 Miles (82 000 km) 84,000 Miles (134 000 km) • Change the engine oil. • Change the engine oil. • Replace the engine oil filter. • Replace the engine oil filter. •...
Page 21 LUBRICATION AND MAINTENANCE 0 - 7 SPECIFICATIONS (Continued) • Replace the ignition cables. 111,000 Miles (178 000 km) • Replace the spark plugs. • Change the engine oil. • Replace the engine oil filter. NOTE: # 1 This maintenance is recommended by DaimlerChrysler Corporation to the owner but is not 114,000 Miles (182 000 km) required to maintain the emissions warranty.
Page 22: Jump Starting, Towing, And Hoisting
0 - 8 LUBRICATION AND MAINTENANCE JUMP STARTING, TOWING, AND HOISTING TABLE OF CONTENTS page page SERVICE PROCEDURES TOWING RECOMMENDATIONS....9 JUMP STARTING PROCEDURE....8 HOISTING RECOMMENDATIONS .
Page 23 LUBRICATION AND MAINTENANCE 0 - 9 SERVICE PROCEDURES (Continued) 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.
Page 24 0 - 10 LUBRICATION AND MAINTENANCE SERVICE PROCEDURES (Continued) CAUTION: Do not use steering column lock to A floor jack or any lifting device, must never be secure steering wheel during towing operation. used on any part of the underbody other then the described areas.
Page 25 Daimler- line. Camber is a tire wearing angle. Chrysler Corporation’s wheel alignment specifica- • Excessive negative camber will cause tread wear tions differ. at the inside of the tire.
Page 26 2 - 2 SUSPENSION DESCRIPTION AND OPERATION (Continued) • Forward tilt (upper ball joint ahead of lower) results in a negative caster angle. • Rearward tilt (upper ball joint trailing lower) results in a positive caster angle. Although caster does not affect tire wear, a caster imbalance between the two front wheels may cause the vehicle to lead to the side with the least positive caster.
Page 27 SUSPENSION 2 - 3 DESCRIPTION AND OPERATION (Continued) Toe is measured in degrees or inches. The mea- TOE-OUT ON TURNS surement identifies the amount that the front of the Toe-out on turns is the relative positioning of the wheels point inward (toe-in) or outward (toe-out). Toe front wheels while steering through a turn (Fig.
Page 28 2 - 4 SUSPENSION DESCRIPTION AND OPERATION (Continued) STEERING AXIS INCLINATION (S.A.I.) THRUST ANGLE Steering axis inclination is the angle between a Thrust angle is the averaged direction the rear true vertical line starting at the center of the tire at wheels are pointing in relation to the vehicle’s center the road contact point and a line drawn through the line (Fig.
Page 29 SUSPENSION 2 - 5 DIAGNOSIS AND TESTING SUSPENSION AND STEERING DIAGNOSIS CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS Front End Whine On Turns 1. Defective Wheel Bearing 1. Replace Wheel Bearing 2. Incorrect Wheel Alignment 2. Check And Reset Wheel Alignment 3. Worn Tires 3.
Page 30 2 - 6 SUSPENSION DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS 6. Worn Or Loose Control Arm 6. Tighten To Specified Torque Or Replace Bushing Control Arm Bushing 7. Loose Crossmember Bolts 7. Tighten Crossmember Bolts To Specified Torque Road Wander 1.
Page 31 SUSPENSION 2 - 7 coil spring height to a correct new or known good coil SERVICE PROCEDURES spring. The heights should vary if the suspect spring is weak. CURB HEIGHT MEASUREMENT The wheel alignment is to be checked and all align- NOTE: Prior to reading the curb height measure- ment adjustments made with the vehicle at its ment, the front an rear of the vehicle should be...
Page 32 2 - 8 SUSPENSION SERVICE PROCEDURES (Continued) (3) Read the vehicle’s current front and rear align- CASTER and FRONT TOE within this wheel align- ment settings. Compare the vehicle’s current align- ment service procedure. ment settings to the vehicle specifications for camber, FRONT CAMBER AND CASTER caster and toe-in.
Page 33 SUSPENSION 2 - 9 SERVICE PROCEDURES (Continued) FRONT TOE (1) Center the steering wheel and lock it in place using a steering wheel clamp. CAUTION: Do not twist the inner tie rod-to-steering gear rubber boots while turning the inner tie rod during the front toe adjustment.
Page 34 2 - 10 SUSPENSION 2001 PT Service Manual Publication No. 81-370-1111 TSB 26-05-00 May, 2000 SPECIFICATIONS NOTE: All wheel alignments are to be set with the vehicle at curb height. Refer to CURB HEIGHT MEA- SUREMENT in SERVICE PROCEDURES. WHEEL ALIGNMENT NOTE: All specifications are given in degrees.
Page 35 SUSPENSION 2 - 11 FRONT SUSPENSION TABLE OF CONTENTS page page DESCRIPTION AND OPERATION STRUT ASSEMBLY (FRONT) ....18 FRONT SUSPENSION SYSTEM ....11 STEERING KNUCKLE .
Page 36 2 - 12 SUSPENSION DESCRIPTION AND OPERATION (Continued) Fig. 1 Front Suspension System...
Page 37 SUSPENSION 2 - 13 DESCRIPTION AND OPERATION (Continued) 1 – UPPER MOUNT 11 – HUB 2 – VEHICLE STRUT TOWER 12 – KNUCKLE 3 – OUTER TIE ROD 13 – STRUT 4 – JAM NUT 14 – LOWER SPRING ISOLATOR 5 –...
Page 38 2 - 14 SUSPENSION DESCRIPTION AND OPERATION (Continued) ance. The ball joint stud is clamped and locked to the STABILIZER BAR (FRONT) steering knuckle lower leg using a pinch bolt. The ball joint is lubricated for life during the man- DESCRIPTION ufacturing process.
Page 39 SUSPENSION 2 - 15 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS Front End Whine With 1. Defective Wheel Bearing 1. Replace Wheel Bearing Vehicle Going Straight At A Constant Speed 2. Incorrect Wheel Alignment 2. Check And Reset Wheel Alignment 3.
Page 40 2 - 16 SUSPENSION DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS Excessive Steering Free 1. Incorrect Steering Gear 1. Adjust Or Replace Steering Gear Play Adjustment 2. Worn Or Loose Tie Rod Ends 2. Replace Or Tighten Tie Rod Ends 3.
Page 41 SUSPENSION 2 - 17 DIAGNOSIS AND TESTING (Continued) Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weapage from the bearing is consid- ered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, refer to BRAKE ROTOR in the DIAGNOSIS AND TESTING section in the BRAKES service manual group for the procedure on...
Page 42 2 - 18 SUSPENSION DIAGNOSIS AND TESTING (Continued) CAUTION: No attempt should be made to service FIBERS IN AN IMPERMEABLE CONTAINER WITH the headless grease fitting on the ball joint. It has THE APPROPRIATE LABEL. FOLLOW PRACTICES been purposely snapped off by the manufacturer to PRESCRIBED BY THE OCCUPATIONAL SAFETY avoid over-greasing.
Page 43 SUSPENSION 2 - 19 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Install the strut assembly into the strut tower, aligning the three studs on the strut upper mount with the holes in strut tower. Install the three mounting nuts on the studs (Fig. 6). Tighten the three nuts to a torque of 34 N·m (25 ft.
Page 44 2 - 20 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 7 Hub Nut 1 – HUB NUT Fig. 9 Tie Rod Removal 2 – NUT LOCK 1 – OUTER TIE ROD 3 – COTTER PIN 2 – STEERING KNUCKLE 4 – SPRING WASHER (11) Remove the nut and pinch bolt clamping the (6) Release the brakes.
Page 45 SUSPENSION 2 - 21 REMOVAL AND INSTALLATION (Continued) (13) Separate the ball joint stud from the steering (2) Slide the hub of the steering knuckle onto the knuckle by prying down on lower control arm and up splines on the driveshaft C/V joint. against the ball joint boss on the steering knuckle (3) Install the steering knuckle onto the ball joint (Fig.
Page 46 2 - 22 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 12 Correctly Installed Cotter Pin 1 – COTTER PIN 2 – NUT LOCK Fig. 13 Stabilizer Bar Links 1 – STABILIZER BAR CUSHION RETAINERS (15) Set the front toe on the vehicle to required 2 –...
Page 47 SUSPENSION 2 - 23 REMOVAL AND INSTALLATION (Continued) (c) Remove the pencil strut from the right front corner of the crossmember and body of the vehicle (Fig. 16). Remove the washer behind the strut from the torque strut bolt. (d) Remove the bolts mounting the engine torque strut in place (Fig.
Page 48 2 - 24 SUSPENSION REMOVAL AND INSTALLATION (Continued) (6) Rotate the forward ends of the stabilizer bar into mounting position. (7) Clean the threads of the stabilizer bar link bolts, then apply Mopar Lock And Seal or equiva- lent to the threads. (8) Install both stabilizer bar links back on vehicle (Fig.
Page 49 SUSPENSION 2 - 25 REMOVAL AND INSTALLATION (Continued) bolts, but do not completely tighten them at this time. (3) Clean the threads of the stabilizer bar link bolts, then apply Mopar Lock And Seal or equiva- lent to the threads. (4) Install both stabilizer bar links back on vehicle (Fig.
Page 50 2 - 26 SUSPENSION REMOVAL AND INSTALLATION (Continued) (2) Tighten the wheel mounting nut. This will pull the wheel mounting stud into the flange of the hub. When the head of the stud is fully seated against the rear of the hub flange, remove the wheel mounting nut and washers from the stud.
Page 51 SUSPENSION 2 - 27 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 23 Strut Assembly In Compressor (Upper) Fig. 25 Strut Assembly Components 1 – NOTCH IN UPPER SEAT 2 – UPPER MOUNT 1 – NUT 3 – UPPER HOOKS 2 – STRUT ASSEMBLY 4 –...
Page 52 2 - 28 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) ASSEMBLY (7) If disassembled, reinstall the upper spring iso- lator on the upper spring seat and bearing. (8) Install the upper spring seat and bearing on NOTE: If the coil spring has been removed from the spring compressor, proceed with the next step, oth- top of the coil spring.
Page 53 SUSPENSION 2 - 29 DISASSEMBLY AND ASSEMBLY (Continued) (2) Three wheel studs across from one another (4) Install the Bearing Splitter, Special Tool 1130, require removal from the hub flange. Rotate the hub between the hub and the bearing retainer plate as to align each wheel mounting stud with the notch in shown (Fig.
Page 54 2 - 30 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) (7) Remove the bearing splitter from the steering (11) Remove the bearing race that is still pressed knuckle. onto the hub. To do so, install Bearing Splitter, Spe- (8) Remove the three bolts mounting the bearing cial Tool 1130, between the hub flange and the bear- retainer plate to the steering knuckle (Fig.
Page 55 SUSPENSION 2 - 31 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 34 Wheel Bearing Installation Fig. 35 Wheel Mounting Stud Installation 1 – PRESS RAM 1 – ARBOR PRESS RAM 2 – BEARING 2 – HUB 3 – SPECIAL TOOL C-4698–1 (6) Noting the notch location, install the bearing 4 –...
Page 56 2 - 32 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) DISASSEMBLY ASSEMBLY (1) Using a screwdriver or other suitable tool, pry CAUTION: When installing a ball joint in its mount- the seal boot off of the ball joint (Fig. 37). ing hole in the lower control arm, position the ball joint so the notch in the ball joint stud is facing the lower control arm front isolator bushing (Fig.
Page 57 SUSPENSION 2 - 33 DISASSEMBLY AND ASSEMBLY (Continued) NOTE: If the ball joint is equipped with a lubeable grease fitting, the joint will need to be lubricated once the lower control arm installation is complete. LOWER CONTROL ARM (REAR ISOLATOR BUSHING) NOTE: The removal and installation of the rear iso- lator bushing from the lower control arm is only to...
Page 58 2 - 34 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) ASSEMBLY (1) Back the ball joint press C-4212F set screw outward so it does not extend out into the cup area (Fig. 43). Fig. 43 Set Screw Backed Outward 1 – SET SCREW 2 –...
Page 59 SUSPENSION 2 - 35 DISASSEMBLY AND ASSEMBLY (Continued) SPECIAL TOOLS FRONT SUSPENSION Splitter, Bearing 1130 Fig. 45 Installing Bushing 1 – LOWER CONTROL ARM FLANGE 2 – ISOLATOR BUSHING SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUE DESCRIPTION TORQUE Installer, Bearing 5052 Lower Control Arm: Front Pivot Bolt .
Page 60 2 - 36 SUSPENSION SPECIAL TOOLS (Continued) Installer 6760 Remover C-4150A Remover 6804 Press, Ball Joint C-4212F Socket/Wrench Strut Nut 6864 Installer Adapter C-4698-2 Remover/Installer 6908 (–2) Remover MB-990799 Remover MB991113 Remover/Installer 8373...
Page 61 SUSPENSION 2 - 37 REAR SUSPENSION TABLE OF CONTENTS page page DESCRIPTION AND OPERATION AXLE ........43 REAR SUSPENSION SYSTEM .
Page 62 2 - 38 SUSPENSION DESCRIPTION AND OPERATION (Continued) Fig. 1 Rear Suspension System 1 – ISOLATORS 5 – WATTS LINK (LOWER) 2 – JOUNCE BUMPER 6 – BELL CRANK 3 – SHOCK ABSORBER 7 – AXLE 4 – WATTS LINK (UPPER) 8 –...
Page 63 SUSPENSION 2 - 39 DESCRIPTION AND OPERATION (Continued) OPERATION The hub and bearing adapts the tire and wheel assembly to the axle mounted spindle. It’s bearing allows the tire and wheel assembly to rotate freely on the vehicle. The brake drum or brake rotor mounts to the hub’s wheel mounting studs aiding in stopping the vehicle when required.
Page 64 2 - 40 SUSPENSION DESCRIPTION AND OPERATION (Continued) Fig. 3 Component Mounting 1 – AXLE 9 – HUB AND BEARING 2 – SEAL 10 – DISC BRAKE ADAPTER 3 – DRUM BRAKE WITH SUPPORT PLATE 11 – SEAL 4 – HUB AND BEARING 12 –...
Page 65 SUSPENSION 2 - 41 DESCRIPTION AND OPERATION (Continued) Fig. 6 Bell Crank 1 – INSTALLATION DIRECTION They are fixed to a set length at the factory and require no maintenance. The bushings on the links are not serviceable. Fig. 5 Stabilizer Bar And Components (Right Side Shown) OPERATION 1 –...
Page 66 2 - 42 SUSPENSION DIAGNOSIS AND TESTING (Continued) COIL SPRING STABILIZER BAR (REAR) Inspect the coil spring for damage. Make sure the Inspect the stabilizer bar and attaching links. Look outer coating is not damaged, leaving the bare coil for damage or bent condition. If damage is evident, exposed.
Page 67 SUSPENSION 2 - 43 AXLE REMOVAL AND INSTALLATION SERVICE WARNINGS AND CAUTIONS WARNING: THE AUTOMATIC ADJUSTING FEATURE OF THIS PARKING BRAKE LEVER CONTAINS A CLOCKSPRING LOADED TO APPROXIMATELY 19 WARNING: DUST AND DIRT ACCUMULATING ON POUNDS. DO NOT RELEASE THE AUTOMATIC BRAKE PARTS DURING NORMAL USE MAY CON- ADJUSTER LOCKOUT DEVICE UNLESS THE REAR TAIN ASBESTOS FIBERS FROM PRODUCTION OR...
Page 68 2 - 44 SUSPENSION REMOVAL AND INSTALLATION (Continued) REMOVAL (1) Unclip the air cleaner cover (two clips) and move the cover aside. (2) Disconnect and isolate the battery negative cable from its post on the battery. (3) Block the tire and wheels so the vehicle does not move once the vehicle parking brake lever is released.
Page 69 SUSPENSION 2 - 45 REMOVAL AND INSTALLATION (Continued) Fig. 9 Rear Brake Mounting To Axle 1 – AXLE 9 – HUB AND BEARING 2 – SEAL 10 – DISC BRAKE ADAPTER 3 – DRUM BRAKE WITH SUPPORT PLATE 11 – SEAL 4 –...
Page 70 2 - 46 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 10 Rear Disc Brakes 1 – DISC BRAKE ADAPTER 2 – GUIDE PIN BOLTS Fig. 11 Parking Brake Shoes 3 – HUB AND BEARING 4 – BRAKE ROTOR 1 – UPPER RETURN SPRING 5 –...
Page 71 SUSPENSION 2 - 47 REMOVAL AND INSTALLATION (Continued) (b) Remove the parking brake cable from the rear disc brake adapter. The parking brake cable can be removed from the disc brake adapter using ⁄ inch offset box wrench to compress the locking fingers on the parking brake cable retainer (Fig.
Page 72 2 - 48 SUSPENSION REMOVAL AND INSTALLATION (Continued) (17) Remove the two bolts on each axle trailing (20) Remove the four bolts securing each brake arm securing the cable and routing brackets to the shoe support plate (drum brakes) or disc brake arm (Fig.
Page 73 SUSPENSION 2 - 49 REMOVAL AND INSTALLATION (Continued) Fig. 19 Rear Suspension 1 – ISOLATORS 5 – WATTS LINK (LOWER) 2 – JOUNCE BUMPER 6 – BELL CRANK 3 – SHOCK ABSORBER 7 – AXLE 4 – WATTS LINK (UPPER) 8 –...
Page 74 2 - 50 SUSPENSION REMOVAL AND INSTALLATION (Continued) (4) Tap the axle trailing arm brackets as necessary to align the brackets to the scribed marks, then tighten the bolts to a torque of 54 N·m (40 ft. lbs.). (5) Install a rubber isolator on each end of the coil springs wrapping the rubber fingers around the coil (Fig.
Page 75 SUSPENSION 2 - 51 REMOVAL AND INSTALLATION (Continued) Fig. 23 Coil Spring Orientation 1 – IMAGINARY LINE (11) Hook the lower ends of the stabilizer bar cushion retainers into the slots in the back of the axle, then rotate the opposite end of the retainers upward so the mounting bolts can be installed.
Page 76 2 - 52 SUSPENSION 2001 PT Service Manual REMOVAL AND INSTALLATION (Continued) Publication No. 81-370-1111 TSB 26-04-01 April, 2001 (12) Install the bolt from the front securing the (24) On drum brake equipped vehicles, install the watts link bell crank to the center of the axle (Fig. brake drums.
Page 77 SUSPENSION 2 - 53 REMOVAL AND INSTALLATION (Continued) AXLE PIVOT BUSHING (5) Move the parking brake cables from their mounting positions away from the bottom of the trailing arm pivot bushing and the forward bracket. NOTE: Before proceeding with this procedure, (6) Remove the bolt securing the watts link bell review SERVICE WARNINGS AND CAUTIONS at the crank to the center of the axle (Fig.
Page 78 2 - 54 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 26 Rear Suspension 1 – ISOLATORS 5 – WATTS LINK (LOWER) 2 – JOUNCE BUMPER 6 – BELL CRANK 3 – SHOCK ABSORBER 7 – AXLE 4 – WATTS LINK (UPPER) 8 –...
Page 79 SUSPENSION 2 - 55 REMOVAL AND INSTALLATION (Continued) (1) Apply Mopar Rubber Bushing Installation Lube to the outside edges of the NEW bushing. Also, lubricate the inside of the Installer, Special Tool 8405-2 with the special lube. (2) Place the stepped end of the Installer on the end of the trailing arm bushing sleeve that has the curved flange at the arm (Fig.
Page 80 2 - 56 SUSPENSION REMOVAL AND INSTALLATION (Continued) (8) Install the trailing arm forward bracket(s) on (13) Install the bolt from the front securing the the axle using the following way: watts link bell crank to the center of the axle (Fig. (a) From above the axle, place the bracket down 26).
Page 81 SUSPENSION 2 - 57 REMOVAL AND INSTALLATION (Continued) Fig. 31 Rear Suspension 1 – ISOLATORS 5 – WATTS LINK (LOWER) 2 – JOUNCE BUMPER 6 – BELL CRANK 3 – SHOCK ABSORBER 7 – AXLE 4 – WATTS LINK (UPPER) 8 –...
Page 82 2 - 58 SUSPENSION REMOVAL AND INSTALLATION (Continued) NOTE: Both ends of the coil spring are identical. Either end of the spring can be the top or bottom. (2) Place the coil springs on top of the axle spring perches. (3) The coil springs require proper orientation to the body when installed.
Page 83 SUSPENSION 2 - 59 REMOVAL AND INSTALLATION (Continued) Fig. 34 Coil Spring Orientation 1 – IMAGINARY LINE HUB AND BEARING (REAR) NOTE: Before proceeding with this procedure, review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section.
Page 84 2 - 60 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 36 Rear Brake Mounting To Axle 1 – AXLE 9 – HUB AND BEARING 2 – SEAL 10 – DISC BRAKE ADAPTER 3 – DRUM BRAKE WITH SUPPORT PLATE 11 – SEAL 4 –...
Page 85 SUSPENSION 2 - 61 REMOVAL AND INSTALLATION (Continued) Fig. 38 Shock Absorber Mounting Fig. 37 Rear Disc Brakes 1 – DISC BRAKE ADAPTER 1 – SHOCK ABSORBER 2 – GUIDE PIN BOLTS 3 – HUB AND BEARING (3) Install the washer and nut on the end of the 4 –...
Page 86 2 - 62 SUSPENSION 2001 PT Service Manual REMOVAL AND INSTALLATION (Continued) Publication No. 81-370-1111 TSB 26-04-01 April, 2001 Fig. 39 Rear Brake Mounting To Axle 1 – AXLE 9 – HUB AND BEARING 2 – SEAL 10 – DISC BRAKE ADAPTER 3 –...
Page 87 SUSPENSION 2 - 63 REMOVAL AND INSTALLATION (Continued) Fig. 40 Rear Disc Brakes 1 – DISC BRAKE ADAPTER 2 – GUIDE PIN BOLTS Fig. 42 Wheel Speed Sensor 3 – HUB AND BEARING 1 – SHOCK ABSORBER 4 – BRAKE ROTOR 2 –...
Page 88 2 - 64 SUSPENSION REMOVAL AND INSTALLATION (Continued) REMOVAL rear axle (Fig. 43). Tighten the rear stabilizer bar cushion retainer bolts at the axle to a torque of 54 (1) Raise the vehicle. Refer to HOISTING in the N·m (40 ft. lbs.). LUBRICATION AND MAINTENANCE group for the (4) Install each stabilizer bar link bolt and nut proper lifting procedure.
Page 89 SUSPENSION 2 - 65 REMOVAL AND INSTALLATION (Continued) STABILIZER BAR LINK (REAR) (4) Install the Remover, Special Tool MB991113, on each link ball joint at the bell crank and release ball joint from the bell crank. NOTE: Before proceeding with this procedure, (5) Remove the pivot bolt and bell crank from the review SERVICE WARNINGS AND CAUTIONS at the vehicle.
Page 90 2 - 66 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 44 Rear Suspension 1 – ISOLATORS 5 – WATTS LINK (LOWER) 2 – JOUNCE BUMPER 6 – BELL CRANK 3 – SHOCK ABSORBER 7 – AXLE 4 – WATTS LINK (UPPER) 8 –...
Page 91 SUSPENSION 2 - 67 REMOVAL AND INSTALLATION (Continued) NOTE: The upper link extends from the right side of the vehicle to the upper end of the bell crank while the lower link extends from the left side of the vehicle to the lower end of the bell crank. (3) Install the upper or lower link to the bell crank (Fig.
Page 92 2 - 68 SUSPENSION REMOVAL AND INSTALLATION (Continued) REMOVAL INSTALLATION (1) Position the hub and bearing assembly under a (1) Install wheel stud into stud hole in hub and hydraulic press ram, supported by a 21 mm. deep bearing assembly. well impact socket under the stud to be replaced (2) Position the hub and bearing assembly face (Fig.
Page 93 SUSPENSION 2 - 69 SPECIFICATIONS SPECIAL TOOLS REAR SUSPENSION FASTENER TORQUE REAR SUSPENSION DESCRIPTION TORQUE Axle: Bracket To Body Bolts ..54 N·m (40 ft. lbs.) Brake/Spindle Bolts ..95 N·m (70 ft. lbs.) Parking Brake Cable Bracket Bolts .
Page 94 DIFFERENTIAL AND DRIVELINE 3 - 1 DIFFERENTIAL AND DRIVELINE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION INNER TRIPOD JOINT SEAL BOOT ... 9 FRONT DRIVESHAFTS ..... 1 OUTER C/V JOINT SEAL BOOT .
Page 95 3 - 2 DIFFERENTIAL AND DRIVELINE DESCRIPTION AND OPERATION (Continued) Fig. 1 Unequal Length Driveshaft System 1 – STUB AXLE 8 – OUTER C/V JOINT 2 – OUTER C/V JOINT 9 – RIGHT DRIVESHAFT 3 – OUTER C/V JOINT BOOT 10 –...
Page 96 DIFFERENTIAL AND DRIVELINE 3 - 3 DIAGNOSIS AND TESTING (Continued) (2) Noise may also be caused by another compo- (1) Disconnect battery negative cable. nent of the vehicle coming in contact with the drive- (2) Place transaxle in gated park. shafts.
Page 97 3 - 4 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (8) Remove nut and bolt (Fig. 5) retaining ball (10) Remove driveshaft from steering knuckle by joint stud into steering knuckle. pulling outward on knuckle while pressing in on driveshaft. Support outer end of driveshaft assembly. If difficulty in separating driveshaft from steering knuckle is encountered, perform the following proce- dure:...
Page 98 DIFFERENTIAL AND DRIVELINE 3 - 5 REMOVAL AND INSTALLATION (Continued) NOTE: Removal of the inner tripod joints is made easier if you apply outward pressure on the joint as you strike the punch with a hammer. (12) Remove the inner tripod joints from the side gears of the transaxle using a punch to dislodge the inner tripod joint retaining ring from the transaxle side gear.
Page 99 3 - 6 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Thoroughly clean spline and oil seal sealing surface, on tripod joint. Lightly lubricate oil seal sealing surface on tripod joint with fresh clean trans- mission lubricant. (2) Holding driveshaft assembly by tripod joint and interconnecting shaft, install tripod joint into tran- saxle side gear as far as possible by hand.
Page 100 DIFFERENTIAL AND DRIVELINE 3 - 7 REMOVAL AND INSTALLATION (Continued) (8) Clean all foreign matter from threads of drive- (11) Check for correct fluid level in transaxle shaft outer stub axle. Install washer and hub nut assembly. Refer to TRANSAXLE for the correct fluid onto the threads of the stub axle and tighten nut to level checking procedure for the type of transaxle 244 N·m (180 ft.
Page 101 3 - 8 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 17 Driveshaft Assembly Components (Exploded View) 1 – RING 11 – BALL 2 – SPIDER 12 – CLAMP 3 – CLAMP 13 – BOOT 4 – BUSHING 14 – CLAMP 5 –...
Page 102 DIFFERENTIAL AND DRIVELINE 3 - 9 DISASSEMBLY AND ASSEMBLY (Continued) INNER TRIPOD JOINT SEAL BOOT (3) Slide the interconnecting shaft and spider assembly out of the tripod joint housing (Fig. 19). REMOVAL To remove sealing boot from driveshaft for replace- ment, the driveshaft assembly must be removed from the vehicle.
Page 103 3 - 10 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 22 Sealing Boot Installation on Interconnecting Fig. 21 Spider Assembly Removal from Shaft Interconnecting Shaft 1 – SEALING BOOT 1 – SPIDER ASSEMBLY 2 – RAISED BEAD IN THIS AREA OF SEALING BOOT 2 –...
Page 104 DIFFERENTIAL AND DRIVELINE 3 - 11 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 24 Installing Spider Assembly On Fig. 26 Installing Tripod Housing on Spider Interconnecting Shaft Assembly 1 – DO NOT HIT BEARINGS WHEN INSTALLING THE SPIDER 1 – TRIPOD JOINT HOUSING ASSEMBLY 2 –...
Page 105 3 - 12 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 28 Sealing Boot Retaining Clamp Installed Fig. 29 Trim Stick Inserted for Venting Tripod Joint 1 – CLAMP 1 – INNER TRIPOD JOINT SEALING BOOT 2 – JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED 2 –...
Page 106 DIFFERENTIAL AND DRIVELINE 3 - 13 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 31 Sealing Boot End to End Length with Fig. 33 Sealing Boot Retaining Clamp Installed Silicone Boot 1 – CLAMP 1 – 115 MILLIMETERS 2 – TRIPOD HOUSING 2 – SILICONE SEALING BOOT 3 –...
Page 107 3 - 14 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) (3) Wipe away grease to expose outer C/V joint and interconnecting shaft. (4) Remove outer C/V joint from interconnecting shaft using the following procedure: Support inter- connecting shaft in a vise equipped with protec- tive caps on jaws of vise to prevent damage to interconnecting shaft.
Page 108 DIFFERENTIAL AND DRIVELINE 3 - 15 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 38 Sealing Boot Installation on Interconnecting Fig. 40 Outer C/V Joint Correctly Installed on Shaft Interconnecting Shaft 1 – SEALING BOOT 1 – INTERCONNECTING SHAFT 2 – RAISED BEAD IN THIS AREA OF SEALING BOOT 2 –...
Page 109 3 - 16 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 42 Sealing Boot Retaining Clamp Installed Fig. 43 Crimping Tool Installed on Sealing Boot 1 – CLAMP Clamp 2 – JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED 1 – CLAMP COMPLETELY TOGETHER HERE 2 –...
Page 110 DIFFERENTIAL AND DRIVELINE 3 - 17 SPECIFICATIONS SPECIAL TOOLS TORQUE DRIVESHAFT DESCRIPTION TORQUE Driveshaft-to-Hub/Bearing Nut ....244 N·m (180 ft. lbs.) Knuckle-to-Ball Joint Bolt/Nut .
Page 112 BRAKES 5 - 1 BRAKES TABLE OF CONTENTS page page BASE BRAKE SYSTEM ..... . 1 ANTILOCK BRAKE SYSTEM ....67 BASE BRAKE SYSTEM TABLE OF CONTENTS page...
Page 113 5 - 2 BRAKES (rear only) and chassis brake tubes to the brakes at DESCRIPTION AND OPERATION each tire and wheel assembly. The parking brakes are hand-operated. When BASE BRAKE SYSTEM applied, the parking brake lever pulls on cables that actuate brake shoes at each rear wheel.
Page 114 BRAKES 5 - 3 DESCRIPTION AND OPERATION (Continued) of the vehicle. It’s main function is to control opera- to the front of the booster (Fig. 3). A vacuum check tion of the vehicle’s brake lamps. Other functions valve is also mounted on the front of the booster. A include speed control deactivation, brake sense for vacuum line connects the check valve to engine the antilock brake system and brake sense for the...
Page 115 5 - 4 BRAKES DESCRIPTION AND OPERATION (Continued) Fig. 5 Non-ABS Master Cylinder Fig. 4 Power Brake Booster 1 – RIGHT FRONT BRAKE TUBE 1 – MOUNTING STUD 2 – PROPORTIONING VALVES 2 – PARTS IDENTIFICATION TAG 3 – LEFT FRONT BRAKE TUBE 3 –...
Page 116 BRAKES 5 - 5 DESCRIPTION AND OPERATION (Continued) Fig. 7 Proportioning Valve Location Fig. 6 Switch Location 1 – RIGHT FRONT BRAKE TUBE 1 – POWER BRAKE BOOSTER 2 – PROPORTIONING VALVES 2 – BRAKE FLUID LEVEL SWITCH 3 – LEFT FRONT BRAKE TUBE 3 –...
Page 117 5 - 6 BRAKES DESCRIPTION AND OPERATION (Continued) 10). The boot prevents contamination in the bore area. Fig. 10 Piston Boot Installation Fig. 8 Front Disc Brake The caliper is mounted to the caliper adapter using 1 – BRAKE ROTOR two guide pin bolts.
Page 118 BRAKES 5 - 7 DESCRIPTION AND OPERATION (Continued) OPERATION When the brakes are applied, fluid pressure is sent to each brake caliper. The pressure at the caliper is exerted equally against the caliper piston. The pres- sure applied to the piston is transmitted directly to the inboard brake shoe.
Page 119 5 - 8 BRAKES DESCRIPTION AND OPERATION (Continued) sary. Fluid level should always be checked after replacing shoes. DRUM BRAKES (REAR) DESCRIPTION Rear drum brakes are standard equipment on this vehicle. The rear drum brakes consist of the major components listed in the figure (Fig. 15). Other com- ponents related to the brake shoes themselves can be seen in the next figure (Fig.
Page 120 BRAKES 5 - 9 DESCRIPTION AND OPERATION (Continued) Fig. 17 Parking Brake Lever 1 – OUTPUT CABLE Fig. 16 Drum Brake Shoes (Left Side Shown) 2 – SWITCH 1 – WHEEL CYLINDER 2 – AUTOMATIC ADJUSTER SCREW ASSEMBLY 3 – RETURN SPRING cable can only be serviced as part of the parking 4 –...
Page 121 5 - 10 BRAKES DESCRIPTION AND OPERATION (Continued) Fig. 19 Drum-In-Hat Brake Rotor Fig. 18 Parking Brake Assembly With Rear Disc 1 – REAR BRAKING DISK ROTOR Brakes 2 – HAT SECTION OF REAR BRAKING DISC (PARKING BRAKE 1 – DISC BRAKE ADAPTER BRAKING SURFACE) 2 –...
Page 122 BRAKES 5 - 11 DIAGNOSIS AND TESTING BASE BRAKE SYSTEM DIAGNOSIS CHARTS NOTE: There are three diagnosis charts following that cover the RED BRAKE WARNING INDICATOR, BRAKE NOISE and OTHER BRAKE CONDITIONS. RED BRAKE WARNING INDICATOR CONDITION POSSIBLE CAUSES CORRECTION RED BRAKE WARNING 1.
Page 123 5 - 12 BRAKES DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 2. Rear brake shoes. 2. Replace rear brake shoes. SCRAPING (METAL-TO- 1. Foreign object interference with 1. Inspect brakes and remove foreign METAL). brakes. object. 2. Brake shoes worn out. 2.
Page 124 BRAKES 5 - 13 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION EXCESSIVE PEDAL 1. Power brake booster runout 1. Check booster vacuum hose and TRAVEL (PEDAL GOES (vacuum assist). engine tune for adequate vacuum TO FLOOR - CAN’T SKID supply.
Page 125 5 - 14 BRAKES DIAGNOSIS AND TESTING (Continued) BRAKE LAMP SWITCH NOTE: Before proceeding with this diagnostic test, verify the adjustment of the brake lamp switch to rule out misadjustment. If misadjusted, replace the switch. It cannot be readjusted. If the electrical circuit has been tested and the brake lamp switch is suspected of being faulty, it can be tested using the following method.
Page 126 BRAKES 5 - 15 DIAGNOSIS AND TESTING (Continued) VACUUM LEAK TEST (1) Disconnect the vacuum hose on the side of the power brake booster vacuum check valve that leads to the speed control, then connect a vacuum gauge to the open vacuum port on the valve. (2) Remove the remaining hose on the vacuum check valve that is not the vacuum supply hose com- ing from the intake manifold.
Page 127 5 - 16 BRAKES DIAGNOSIS AND TESTING (Continued) Fig. 25 Pressure Gauge Set Fig. 23 Brake Pedal Holding Tool 1 – SPECIAL TOOL C-4007–A (5) Install the Brake Pressure Adapters, Special Tool 8644 and 8187-2 onto the proportioning valve inlet gauge is at the target inlet pressure shown in (Fig.
Page 128 BRAKES 5 - 17 DIAGNOSIS AND TESTING (Continued) BRAKE ROTOR Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action. Excessive runout or wobble in a rotor can increase pedal travel due to piston knock-back. This increases guide pin sleeve wear due to the tendency of the cal- iper to follow the rotor wobble.
Page 129 5 - 18 BRAKES DIAGNOSIS AND TESTING (Continued) the rotor. (The hub and rotor runouts are separable). To measure rotor runout on the vehicle, first remove the tire and wheel assembly. Reinstall the wheel mounting nuts on the studs, tightening the rotor to the hub.
Page 130 BRAKES 5 - 19 DIAGNOSIS AND TESTING (Continued) If the hub runout does not exceed this specifica- tion, install the rotor back on the hub, aligning the chalk marks on the rotor with a wheel mounting stud, two studs apart from the original stud (Fig. 31). Tighten nuts in the proper sequence and torque to specifications.
Page 131 5 - 20 BRAKES DIAGNOSIS AND TESTING (Continued) BASE BRAKE BLEEDING NOTE: For bleeding the ABS hydraulic system, refer to Antilock Brake System Bleeding in the Antilock Brake System section. CAUTION: Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder res- ervoir.
Page 132 BRAKES 5 - 21 SERVICE PROCEDURES (Continued) Fig. 33 Proper Method for Purging Air From Brake Fig. 34 Special Tool 6921 System (Typical) 1 – MASTER CYLINDER FLUID RESERVOIR 1 – CLEAR HOSE 2 – BRAKE CALIPER (7) Check the brake pedal travel. If pedal travel is 3 –...
Page 133 5 - 22 BRAKES SERVICE PROCEDURES (Continued) Fig. 36 On-Car Brake Lathe Fig. 35 Bleeding Master Cylinder 1 – ON-CAR BRAKE LATHE 1 – WOODEN DOWEL 2 – MASTER CYLINDER NOTE: It is not necessary to bleed the entire hydraulic system after replacing just the master cyl- inder unless the brake system has been open to air for an excessive amount of time or air is present in the lines.
Page 134 BRAKES 5 - 23 SERVICE PROCEDURES (Continued) BRAKE ROTOR LIMITS Minimum Rotor Rotor Braking Rotor Rotor Thickness Rotor Thickness Runout* Thickness Variation 22.91–23.10 mm 21.40 mm 0.010 mm 0.13 mm Front Rotor 0.902–0.909 in. 0.803 in. 0.0004 in. 0.005 in. 8.75–9.25 mm 7.25 mm 0.013 mm...
Page 135 5 - 24 BRAKES SERVICE PROCEDURES (Continued) CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND, OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESI- DUE. DO NOT CLEAN BRAKE PARTS WITH COM- PRESSED AIR OR BY DRY BRUSHING.
Page 136 BRAKES 5 - 25 REMOVAL AND INSTALLATION (Continued) BRAKE PEDAL (WITH AUTOMATIC TRANSAXLE) NOTE: Before proceeding with this procedure, review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section. REMOVAL (1) Unclip the air cleaner cover (two clips) and move the cover aside.
Page 137 5 - 26 BRAKES REMOVAL AND INSTALLATION (Continued) (9) Tighten the two upper nuts securing the brake BRAKE PEDAL (WITH MANUAL TRANSAXLE) pedal bracket to the instrument panel support to a torque of 34 N·m (300 in. lbs.). NOTE: Before proceeding with this procedure, (10) Install the power brake booster input rod on review SERVICE WARNINGS AND CAUTIONS at the the pin mounted on the side of the brake pedal.
Page 138 BRAKES 5 - 27 REMOVAL AND INSTALLATION (Continued) (4) Once the pedal bushings line up with the mounting holes in the bracket, install the pivot shaft through the pedal from the left side (Fig. 45). (5) Install the pivot shaft nut (Fig. 45). Tighten the nut to a torque of 34 N·m (300 in.
Page 139 5 - 28 BRAKES REMOVAL AND INSTALLATION (Continued) • Install the switch in its bracket by aligning the BRAKE LAMP SWITCH index tab on the switch with the slot in the mounting bracket. NOTE: Before proceeding with this procedure, • When the switch is fully seated in its bracket, review SERVICE WARNINGS AND CAUTIONS at the rotate the switch clockwise approximately 30°...
Page 140 BRAKES 5 - 29 REMOVAL AND INSTALLATION (Continued) (1) With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm. (2) Unclip the air cleaner cover (two clips) and move the cover aside. (3) Remove the air cleaner housing by pulling straight up.
Page 141 5 - 30 BRAKES REMOVAL AND INSTALLATION (Continued) BRAKE FLUID RESERVOIR NOTE: Before proceeding with this procedure, review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section. NOTE: The master cylinder does not need to be removed from the power brake booster for removal and installation of the brake fluid reservoir.
Page 142 BRAKES 5 - 31 REMOVAL AND INSTALLATION (Continued) expanded on the other side of the reservoir, locking it (8) Disconnect the vacuum hoses from the check in place (Fig. 51). valve on the power brake booster (Fig. 54), but do not (2) Connect the brake fluid level switch wiring remove the check valve from power brake booster.
Page 143 5 - 32 BRAKES REMOVAL AND INSTALLATION (Continued) CAUTION: Discard the used retaining clip, it is not removed for some service, a new switch must be to be reused. Replace the clip with a new one on installed and adjusted. reassembly.
Page 144 BRAKES 5 - 33 REMOVAL AND INSTALLATION (Continued) (4) Remove the brake pedal holder (Fig. 57). (5) Bleed the affected brake line. See BASE BRAKE BLEEDING in the SERVICE PROCE- DURES section. (6) Road test the vehicle to ensure proper opera- tion of the brakes.
Page 145 5 - 34 BRAKES 2001 PT Service Manual REMOVAL AND INSTALLATION (Continued) Publication No. 81-370-1111 TSB 26-01-02 January, 2002 REMOVAL (5) Remove the two brake caliper guide pin bolts (Fig. 60). (1) Using a brake pedal holding tool as shown (Fig. (6) Remove the disc brake caliper from the disc 59), depress the brake pedal past its first one inch of brake adapter.
Page 146 BRAKES 5 - 35 REMOVAL AND INSTALLATION (Continued) (7) Remove the two bolts securing the disc brake caliper adapter to the steering knuckle (Fig. 61). (8) Remove the disc brake caliper adapter. INSTALLATION (1) Install the disc brake caliper adapter on the steering knuckle.
Page 147 5 - 36 BRAKES REMOVAL AND INSTALLATION (Continued) (3) Install the disc brake caliper over the brake shoes on the brake caliper adapter. Make sure the springs on the shoes do not get caught in the hole formed into the center of the caliper housing. (4) Align the caliper guide pin bolt holes with the guide pins.
Page 148 BRAKES 5 - 37 REMOVAL AND INSTALLATION (Continued) (4) Remove the disc brake caliper from the disc (3) Install the disc brake caliper over the brake brake adapter and hang out of the way using wire or shoes on the brake caliper adapter. Make sure the a bungee cord.
Page 149 5 - 38 BRAKES REMOVAL AND INSTALLATION (Continued) (2) Raise the vehicle. Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure. (3) Remove the rear tire and wheel assembly. (4) Remove the banjo bolt connecting the brake hose to the brake caliper (Fig.
Page 150 BRAKES 5 - 39 REMOVAL AND INSTALLATION (Continued) (4) Carefully install the caliper guide pin bolts (Fig. 70), then tighten them to a torque of 22 N·m (192 in. lbs.). (5) Install the banjo bolt connecting the brake hose to the brake caliper (Fig. 69). Install NEW washers. Place one fitting washer on each side of the hose fit- ting as the banjo bolt is guided through the fitting.
Page 151 5 - 40 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 72 Caliper And Rotor Mounting 1 – DISC BRAKE ADAPTER 2 – GUIDE PIN BOLTS 3 – HUB AND BEARING 4 – BRAKE ROTOR 5 – RETAINER CLIP 6 – DUST CAP Fig.
Page 152 BRAKES 5 - 41 REMOVAL AND INSTALLATION (Continued) BRAKE ROTOR (REAR) REMOVAL (1) Raise the vehicle. Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure. (2) Remove the rear tire and wheel assembly. (3) Remove the rear disc brake caliper assembly from the brake rotor and store it out of the way.
Page 153 5 - 42 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 77 Brake Pedal Holder Fig. 79 Drum Brakes (4) Disconnect the rear brake flex hose from the 1 – WHEEL CYLINDER wheel cylinder (Fig. 78). 2 – SEAL 3 – SUPPORT PLATE 4 –...
Page 154 BRAKES 5 - 43 REMOVAL AND INSTALLATION (Continued) (10) Bleed the wheel cylinder as necessary. Refer to BASE BRAKE BLEEDING in the SERVICE PRO- CEDURES section in this service manual group. (11) Road test the vehicle to make sure the brakes operate correctly.
Page 155 5 - 44 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 83 Hold Down Clips And Pins Fig. 85 Parking Brake Lever Pin To Brake Shoe Retaining Clip 1 – HOLD DOWN CLIP 2 – BRAKE SHOE 1 – RETAINING CLIP 3 – SUPPORT PLATE 2 –...
Page 156 BRAKES 5 - 45 REMOVAL AND INSTALLATION (Continued) (10) Install the automatic adjustment lever-to- brake shoe spring (Fig. 81). Do not overstretch the spring when installing. (11) Adjust the brake shoes to the drum diameter using a brake shoe gauge. Refer to ADJUSTMENTS in this section.
Page 157 5 - 46 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 90 Brake Pedal Holding Tool Fig. 89 Drum Brakes 1 – WHEEL CYLINDER 2 – SEAL 3 – SUPPORT PLATE 4 – BRAKE SHOES 5 – RETAINER CLIP 6 – DUST CAP 7 –...
Page 158 BRAKES 5 - 47 2001 PT Service Manual REMOVAL AND INSTALLATION (Continued) Publication No. 81-370-1111 TSB 26-04-01 April, 2001 INSTALLATION (1) Apply a bead of fresh Mopar RTV sealer or equivalent around the mating surface of the wheel cylinder and brake support plate. NOTE: Once sealer is applied, install the wheel cyl- inder within several minutes to avoid excessive hardening of the sealer before installation.
Page 159 5 - 48 BRAKES REMOVAL AND INSTALLATION (Continued) PARKING BRAKE LEVER WARNING: THE AUTOMATIC ADJUSTING FEATURE OF THIS PARKING BRAKE LEVER CONTAINS A CLOCK SPRING LOADED TO APPROXIMATELY 19 POUNDS. DO NOT RELEASE THE AUTOMATIC ADJUSTER LOCKOUT DEVICE UNLESS THE REAR PARKING BRAKE CABLES AND EQUALIZER ARE CONNECTED TO THE LEVER OUTPUT CABLE.
Page 160 BRAKES 5 - 49 REMOVAL AND INSTALLATION (Continued) (12) Reinstall the air cleaner cover (two clips). PARKING BRAKE CABLE WARNING: THE AUTOMATIC ADJUSTING FEATURE OF THIS PARKING BRAKE LEVER CONTAINS A CLOCK SPRING LOADED TO APPROXIMATELY 19 POUNDS. DO NOT RELEASE THE AUTOMATIC ADJUSTER LOCKOUT DEVICE UNLESS THE REAR PARKING BRAKE CABLES AND EQUALIZER ARE CONNECTED TO THE LEVER OUTPUT CABLE.
Page 161 5 - 50 BRAKES REMOVAL AND INSTALLATION (Continued) (5) Remove the screws attaching the center con- (8) Remove the rear seat cushion from the vehicle. sole, then remove the center console. (9) Fold the rear carpeting forward to expose the (6) Grasp the parking brake lever output cable by parking brake cables at the end of the rear floor.
Page 162 BRAKES 5 - 51 REMOVAL AND INSTALLATION (Continued) (18) To remove the rear parking brake cable from the brake support plate on vehicles equipped with rear drum brakes: • Remove the parking brake cable from the park- ing brake actuating lever (Fig. 102). •...
Page 163 5 - 52 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 104 Parking Brake Cable Removal Fig. 106 Parking Brake Cable Removal 1 – PARK BRAKE CABLE 1 – CABLE RETAINER 2 – 1/2 WRENCH 2 – OFFSET BOX WRENCH 3 – REAR BRAKE SUPPORT PLATE 3 –...
Page 164 BRAKES 5 - 53 REMOVAL AND INSTALLATION (Continued) (2) Guide the other end of the cable through the NOTE: The parking brake lever can only be in the hole in the axle trailing arm. released position when releasing the automatic (3) Align the cable routing brackets with their adjuster.
Page 165 5 - 54 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 110 Brake Shoe Lower Return Spring Fig. 108 Rear Brake Shoe Hold-Down Clip 1 – LOWER SPRING 1 – HOLD DOWN CLIP Fig. 111 Brake Shoe and Upper Spring Fig. 109 Parking Brake Shoe Adjuster Assembly 1 –...
Page 166 BRAKES 5 - 55 REMOVAL AND INSTALLATION (Continued) Fig. 113 Measuring Brake Shoes 1 – REAR PARKING BRAKE SHOES 2 – BRAKE SHOE GAUGE Fig. 112 Front Hold Down Clip And Brake Shoe 1 – FRONT BRAKE SHOE ASSEMBLY (14) Adjust the parking brake shoes as necessary. 2 –...
Page 167 5 - 56 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) (2) Place a wooden block in the caliper as shown (Fig. 114). Fig. 115 Piston Seal Removal 1 – TRIM STICK 2 – SEAL NOTE: Never use an old piston seal. Fig. 114 Piston Removal (1) Dip the new piston seal in clean brake fluid 1 –...
Page 168 BRAKES 5 - 57 DISASSEMBLY AND ASSEMBLY (Continued) same time, pull the sleeve out the back of the caliper and bushing (Fig. 119). Fig. 117 Boot Installation CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cock- ing and binding of the piston.
Page 169 5 - 58 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) Fig. 120 Removing Bushing From Caliper Fig. 122 Installing Caliper Guide Pin Bushing 1 – CALIPER 1 – CALIPER 2 – BUSHING 2 – BUSHING Fig. 121 Folded Caliper Guide Pin Bushing 1 –...
Page 170 BRAKES 5 - 59 DISASSEMBLY AND ASSEMBLY (Continued) CALIPER PISTON AND SEALS CALIPER PISTON REMOVAL WARNING: UNDER NO CONDITION SHOULD HIGH PRESSURE AIR EVER BE USED TO REMOVE A PIS- TON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. NOTE: The safest way to remove the piston from the caliper bore is to use the hydraulic pressure of the vehicle’s brake system.
Page 171 5 - 60 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) ally be cleared of the light scratches or corrosion using crocus cloth. Bores that have deep scratches or scoring should be honed. Use Caliper Hone, Special Tool C-4095, or the equivalent to hone the bore. Do not over-hone the bore.
Page 172 BRAKES 5 - 61 DISASSEMBLY AND ASSEMBLY (Continued) gently worked around and into the groove (Fig. 129) using only your clean fingers to seat it. Fig. 129 Installing New Piston Seal Fig. 130 Installing Piston Into Caliper Bore 1 – CALIPER 1 –...
Page 173 5 - 62 BRAKES and install a new seal and boot, and a piston if it is CLEANING AND INSPECTION scored. Refer to DISC BRAKE CALIPER in the DIS- ASSEMBLY AND ASSEMBLY section in this section BRAKE TUBES AND HOSES of this service manual group.
Page 174 BRAKES 5 - 63 CLEANING AND INSPECTION (Continued) DRUM BRAKES (REAR) ADJUSTMENTS BRAKE SHOES DRUM BRAKE SHOES Clean the rear brake shoes and springs with a (1) Verify the parking brake lever is in the fully water-dampened cloth or with a brake cleaner. Do released position.
Page 175 5 - 64 BRAKES ADJUSTMENTS (Continued) parking brakes can readjust themselves to the new brake shoe adjustment. PARKING BRAKE SHOES (REAR DISC BRAKES) NOTE: The parking brake shoes used in the drum- in-hat park brake system do not automatically adjust to compensate for brake shoe lining wear. Therefore, it is necessary to manually adjust the parking brake shoes.
Page 176 BRAKES 5 - 65 2001 PT Service Manual ADJUSTMENTS (Continued) Publication No. 81-370-1111 TSB 26-01-02 January, 2002 tire and wheel assembly to ensure that the parking Actuation: brake shoes are working. Proportioning Valve: (9) With the parking brake lever in the released Material .
Page 177 5 - 66 BRAKES SPECIAL TOOLS BASE BRAKE SYSTEM Dial Indicator C-3339 Cap Adapter, Brake Pressure Bleeder 6921 Gauge Set C-4007-A Adapters, Brake Pressure 8187 Handle, Universal C-4171 Tubes, Master Cylinder Bleed 8358 Installer, Dust Boot C-4689 Adapter, Brake Pressure 8644...
Page 178 BRAKES 5 - 67 ANTILOCK BRAKE SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION SERVICE PROCEDURES ANTILOCK BRAKE SYSTEM ....67 BRAKE FLUID LEVEL CHECKING ... . 79 ANTILOCK BRAKE SYSTEM COMPONENTS .
Page 179 5 - 68 BRAKES DESCRIPTION AND OPERATION (Continued) During an ABS stop, the brakes hydraulic system vehicle is first driven off, a humming may be heard is still diagonally split. However, the brake system or felt by the driver at approximately 25–40 km/h pressure is further split into four control channels.
Page 180 BRAKES 5 - 69 DESCRIPTION AND OPERATION (Continued) Fig. 1 Master Cylinder And ICU Fig. 2 Integrated Control Unit (ICU) 1 – MASTER CYLINDER 1 – HCU 2 – CAB CONNECTOR 2 – PUMP/MOTOR CONNECTOR 3 – ICU 3 – CAB 4 –...
Page 181 5 - 70 BRAKES DESCRIPTION AND OPERATION (Continued) The CAB continuously monitors the speed of each tion which can be found elsewhere in this section. wheel through the signals generated by the wheel For information on the operation of the components speed sensors to determine if any wheel is beginning within the HCU, refer to the following three topics.
Page 182 BRAKES 5 - 71 DESCRIPTION AND OPERATION (Continued) common electric motor (Fig. 2). This DC-type motor brake system is affected; The electronic brake distri- is integral to the HCU and is controlled by the CAB. bution (EBD), the base brake system and the ability The pump/motor provides the extra amount of to stop the vehicle are not affected.
Page 183 5 - 72 BRAKES DESCRIPTION AND OPERATION (Continued) Fig. 6 Right Rear Wheel Speed Sensor Fig. 4 Right Front Wheel Speed Sensor 1 – SHOCK ABSORBER 1 – RIGHT FRONT WHEEL SPEED SENSOR 2 – RIGHT REAR WHEEL SPEED SENSOR 2 –...
Page 184 BRAKES 5 - 73 DESCRIPTION AND OPERATION (Continued) released) the fluid in the LPA drains back to the control mode. Traction control operation proceeds in master cylinder by switching on the outlet valve and the following order: draining through the inlet valve check valve. At the (1) Close the normally open traction control (TC) same time the inlet valve is switched on in case of valves.
Page 185 5 - 74 BRAKES DESCRIPTION AND OPERATION (Continued) NORMAL BRAKING HYDRAULIC CIRCUIT, wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than is allowed by SOLENOID VALVE, AND SHUTTLE VALVE the surface on which the tires are riding. FUNCTION (ABS WITH TRACTION CONTROL) •...
Page 186 BRAKES 5 - 75 DESCRIPTION AND OPERATION (Continued) Fig. 9 ABS With Traction Control - ABS Braking Hydraulic Circuit 1 – OUTLET VALVE 9 – NORMALLY OPEN ASR VALVE (OFF) 2 – PUMP PISTON 10 – FROM MASTER CYLINDER 3 – PUMP MOTOR (ON) 11 –...
Page 187 5 - 76 BRAKES DESCRIPTION AND OPERATION (Continued) Fig. 10 Traction Control Hydraulic Circuit 1 – OUTLET VALVE 10 – FROM MASTER CYLINDER 2 – PUMP PISTON 11 – HYDRAULIC SHUTTLE VALVE 3 – PUMP MOTOR (ON) 12 – CONTROLLED WHEEL PRESSURE 4 –...
Page 188 BRAKES 5 - 77 DIAGNOSIS AND TESTING (Continued) ABS GENERAL DIAGNOSTICS INFORMATION (1) Turn the key to the OFF position and then back to the ON position. Note whether the amber This section contains information necessary to ABS warning indicator continues to stay on. If it diagnose the antilock brake system.
Page 189 5 - 78 BRAKES DIAGNOSIS AND TESTING (Continued) ABS SELF-DIAGNOSIS warning indicators that are turned on are only turned on as long as the DTC condition exists; as The ABS system is equipped with a self-diagnosis soon as the condition goes away, the amber ABS capability, which may be used to assist in the isola- warning indicator is turned off, although, in most tion of ABS faults.
Page 190 BRAKES 5 - 79 DIAGNOSIS AND TESTING (Continued) The following trouble conditions may result in wheel runout is excessive, determine if it is caused intermittent illumination of the amber ABS warning by a defect in the driveshaft assembly or hub and indicator.
Page 191 5 - 80 BRAKES SERVICE PROCEDURES (Continued) level periodically during the bleeding procedure and (2) Attach Master Cylinder Bleed Tube, Special add DOT 3 brake fluid as required. Tool 8358-1, to the primary port of the master cylin- The ABS must be bled as two independent braking der and tighten in place (Fig.
Page 192 BRAKES 5 - 81 REMOVAL AND INSTALLATION (Continued) This section contains information on precautions per- REMOVAL taining to potential component damage, vehicle dam- age and personal injury which could result when CAUTION: The vacuum in the power brake booster servicing an ABS equipped vehicle. must be pumped down before removing the master cylinder to prevent the booster from sucking in any CAUTION: Only the recommended jacking or hoist-...
Page 193 5 - 82 BRAKES REMOVAL AND INSTALLATION (Continued) INTEGRATED CONTROL UNIT NOTE: Before proceeding with this procedure, review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section. REMOVAL CAUTION: The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination.
Page 194 BRAKES 5 - 83 REMOVAL AND INSTALLATION (Continued) (8) Disconnect the two brake tubes from the mas- ter cylinder primary and secondary ports (Fig. 16). Install plugs at all of the open brake tube outlets on the master cylinder. Fig. 17 ICU Connections 1 –...
Page 195 5 - 84 BRAKES REMOVAL AND INSTALLATION (Continued) NOTE: When installing the brake tubes from the master cylinder on the HCU, the brake tube with the small tube nut is to be installed in the forward-most port on the HCU with the small end going toward the master cylinder secondary port.
Page 196 BRAKES 5 - 85 REMOVAL AND INSTALLATION (Continued) (6) Remove the screw securing the wheel speed WHEEL SPEED SENSOR (REAR) sensor to the rear of the strut (Fig. 20). Remove the wheel speed sensor. NOTE: Before proceeding with this procedure, review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section.
Page 197 5 - 86 BRAKES REMOVAL AND INSTALLATION (Continued) (5) Remove the bolt attaching the wheel speed sen- DISASSEMBLY AND ASSEMBLY sor to the rear disc brake adapter (Fig. 22), then carefully remove the sensor head from the rear disc INTEGRATED CONTROL UNIT brake adapter and vehicle.
Page 198 BRAKES 5 - 87 2001 PT Service Manual DISASSEMBLY AND ASSEMBLY (Continued) Publication No. 81-370-1111 TSB 26-01-02 January, 2002 REAR TONE WHEEL: Maximum Runout ..0.25 mm (0.009 in.) WHEEL SPEED SENSOR AIR GAP FRONT WHEEL: Minimum .
Page 200 2001 PT CRUISER BRAKES 5a - 1 BRAKES TABLE OF CONTENTS page page DESCRIPTION AND OPERATION POWER BRAKE BOOSTER – RHD ... . 2 BRAKE SYSTEM - RHD ....1 INTEGRATED CONTROL UNIT - RHD.
Page 201 2001 PT CRUISER 5a - 2 BRAKES REMOVAL AND INSTALLATION (Continued) (3) Install master cylinder on brake booster and install retaining nuts. Torque the nuts to 28 N·m (255 in. lbs.). (4) Install the brake lines on master cylinder. Torque brake lines to 17 N·m (150 in. lbs.). (5) Connect fluid level switch wire on the master cylinder.
Page 202 2001 PT CRUISER BRAKES 5a - 3 REMOVAL AND INSTALLATION (Continued) (2) From under the instrument panel, install booster mounting nuts. Tighten nuts just enough to hold booster in place. NOTE: Lubricate the pedal pin and bushing with Mopar multi-mileage grease before installation. (3) Slide booster push rod onto the brake pedal pin.
Page 203 2001 PT CRUISER 5a - 4 BRAKES REMOVAL AND INSTALLATION (Continued) (8) Bleed the base and the ABS hydraulic systems. SPECIFICATIONS Refer to ANTILOCK BRAKE SYSTEM BLEEDING in this section. TORQUE SPECIFICATIONS (9) Fill the master cylinder to the proper fill level. (10) Road test the vehicle to ensure proper opera- DESCRIPTION TORQUE...
Page 204 CLUTCH 6 - 1 CLUTCH TABLE OF CONTENTS page page DESCRIPTION AND OPERATION CLUTCH INTERLOCK/UPSTOP SWITCH..8 MODULAR CLUTCH ASSEMBLY....1 REMOVAL AND INSTALLATION CLUTCH RELEASE BEARING AND FORK .
Page 205 6 - 2 CLUTCH DESCRIPTION AND OPERATION (Continued) CLUTCH RELEASE BEARING AND FORK DESCRIPTION A conventional release bearing is used to engage and disengage the clutch pressure plate. The clutch release bearing is mounted on the transaxle front bearing retainer. The bearing is attached to and oper- ated by the release fork (Fig.
Page 206 CLUTCH 6 - 3 DESCRIPTION AND OPERATION (Continued) FLUID—CLUTCH HYDRAULIC DESCRIPTION CAUTION: Never use any type of petroleum-based fluid (engine oil, transmission oil, power steering fluid, etc.) in the clutch hydraulic system. Use of such fluids will result in master/slave cylinder seal damage, and cause a failure of the hydraulic clutch release system.
Page 207 6 - 4 CLUTCH DESCRIPTION AND OPERATION (Continued) Fig. 7 Clutch Master Cylinder Fig. 8 Slave Cylinder Mounting 1 – RESERVOIR 1 – SLAVE CYLINDER 2 – MASTER CYLINDER 3 – ADJUSTMENT SCREW 4 – QUICK CONNECT OPERATION The clutch master cylinder (Fig. 7) produces the hydraulic pressure necessary to disengage the clutch.
Page 208 CLUTCH 6 - 5 DESCRIPTION AND OPERATION (Continued) OPERATION Clutch Interlock Switch The clutch interlock switch prevents engine starter operation and inadvertent vehicle movement with the clutch engaged and the transaxle in gear. The switch is open while the clutch pedal is at rest.
Page 209 6 - 6 CLUTCH DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION Too much grease applied to splines Apply lighter coating of grease to splines of disc and input shaft NO FAULT FOUND WITH Problem actually related to Further diagnosis required. Check CLUTCH suspension or driveline component engine/transmission mounts, suspension...
Page 210 CLUTCH 6 - 7 DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—IMPROPER CLUTCH RELEASE CONDITION POSSIBLE CAUSES CORRECTION CLUTCH DISC BINDS ON Clutch disc hub splines damaged Clean, smooth, and lubricate disc and shaft INPUT SHAFT SPLINES during installation splines. Replace modular clutch assembly and/or input shaft if splines are severely damaged.
Page 211 6 - 8 CLUTCH DIAGNOSIS AND TESTING (Continued) (5) Check to see if the release bearing is sticky or binding. Replace bearing, if needed. (6) Check linkage for excessive wear on the pivot stud and fork fingers. Replace all worn parts. (7) Check clutch assembly for contamination (dirt, oil).
Page 212 CLUTCH 6 - 9 DIAGNOSIS AND TESTING (Continued) visually inspect the clutch pedal for obstructions (3) Depress clutch pedal at least 33 mm (1.30 in.). (floor mat, etc.). Also make sure the clutch pedal Speed control operation should terminate. If speed blade contacts and fully control does not terminate, the upstop switch is defective or the related wiring is shorted.
Page 213 6 - 10 CLUTCH REMOVAL AND INSTALLATION CLUTCH INTERLOCK/UPSTOP SWITCH REMOVAL (1) Disconnect and isolate battery negative cable. (2) Remove left lower instrument panel bezel (Fig. 14). Fig. 15 Brake Booster Mounting Nuts and Rod Retaining Clip 1 – CLIP 2 –...
Page 214 CLUTCH 6 - 11 REMOVAL AND INSTALLATION (Continued) Fig. 18 Clutch Master Cylinder Pushrod Adjustment Screw 1 – ADJUSTMENT SCREW MODULAR CLUTCH ASSEMBLY Fig. 17 Interlock/Upstop Switch REMOVAL 1 – UPSTOP SWITCH (1) Raise hood. 2 – INTERLOCK SWITCH (2) Disconnect both battery cables. 3 –...
Page 215 6 - 12 CLUTCH REMOVAL AND INSTALLATION (Continued) (4) Remove battery hold down clamp and bolt, and remove battery (Fig. 20). Fig. 22 Back-up Lamp Switch Connector 1 – CONNECTOR Fig. 20 Battery Removal/Installation 2 – BACK UP LAMP SWITCH 1 –...
Page 216 CLUTCH 6 - 13 REMOVAL AND INSTALLATION (Continued) Fig. 26 Clutch Slave Cylinder Connection 1 – SLAVE CYLINDER 2 – HYDRAULIC TUBE Fig. 24 Vehicle Speed Sensor Connector (13) Disconnect power steering hose from struc- 1 – CONNECTOR tural collar (Fig. 27) 2 –...
Page 217 6 - 14 CLUTCH REMOVAL AND INSTALLATION (Continued) Fig. 30 Right Lateral Bending Brace Removal/ Installation—Typical Fig. 28 Left Lateral Bending Brace and Structural 1 – TRANSAXLE Collar 2 – ENGINE 3 – LATERAL BENDING BRACE Fig. 29 Bellhousing Dust Cover Removal/Installation 1 –...
Page 218 CLUTCH 6 - 15 REMOVAL AND INSTALLATION (Continued) (2) Install transaxle-to-engine mounting bolts (Fig. 33) and tighten to 108 N·m (80 ft. lbs.) torque. (3) Raise engine and transaxle with screw jack until upper mount bracket aligns with upper mount. Install mount bolts and tighten to 68 N·m (50 ft.
Page 219 6 - 16 CLUTCH REMOVAL AND INSTALLATION (Continued) (14) Connect clutch master cylinder tube to the hydraulic clutch slave cylinder (Fig. 26). An audible click should be heard. Verify connection by pushing and pulling quick connect. (15) Lower vehicle. (16) Connect vehicle speed sensor connector (Fig. 24).
Page 220 CLUTCH 6 - 17 REMOVAL AND INSTALLATION (Continued) Fig. 37 Slave Cylinder and Hydraulic Supply Tube 1 – SLAVE CYLINDER 2 – HYDRAULIC TUBE Fig. 35 Air Cleaner Assembly Removal/Installation 1 – AIR CLEANER ASSEMBLY (8) Remove lower instrument panel bezel (Fig. 38). Fig.
Page 221 6 - 18 CLUTCH REMOVAL AND INSTALLATION (Continued) (15) Remove master cylinder from mounting posi- tion and carefully work hydraulic pipe from out of engine compartment (Fig. 41). If necessary, unfasten ABS module and purge solenoid assembly to gain necessary clearance. Fig.
Page 222 CLUTCH 6 - 19 REMOVAL AND INSTALLATION (Continued) Fig. 42 Clutch Pedal Adjustment 1 – ADJUSTMENT SCREW Fig. 43 Disconnect Quick-Connect Using Tool 6638A 1 – QUICK CONNECT FITTING (8) Replace stop lamp switch. Refer to Stop Lamp 2 – TOOL 6638A Switch Removal and Installation.
Page 223 6 - 20 CLUTCH REMOVAL AND INSTALLATION (Continued) (2) Tighten slave cylinder bolts to 19 N·m (170 in. grease may be thrown off during operation, contami- lbs.) torque. nating the disc. (3) Tighten damper nuts to 23 N·m (200 in. lbs.) ROAD SPLASH/WATER CONTAMINATION torque.
Page 224 2001 PT CRUISER CLUTCH 6a - 1 CLUTCH TABLE OF CONTENTS page page REMOVAL AND INSTALLATION CLUTCH MASTER CYLINDER....2 CLUTCH INTERLOCK/UPSTOP SWITCH..1 REMOVAL AND INSTALLATION (3) Remove interlock and upstop switches from pedal bracket assembly (Fig.
Page 225 2001 PT CRUISER 6a - 2 CLUTCH REMOVAL AND INSTALLATION (Continued) CLUTCH MASTER CYLINDER REMOVAL NOTE: Replacement master cylinder assemblies come pre-filled with fluid. No fluid service or sys- tem bleeding should be required. (1) Remove air cleaner assembly (Fig. 3). Fig.
Page 226 2001 PT CRUISER CLUTCH 6a - 3 REMOVAL AND INSTALLATION (Continued) (5) Remove hydraulic hose from left rail retainer (8) Disconnect clutch master cylinder rod from (Fig. 6). clutch pedal. (9) Remove coolant recovery bottle. (10) Remove clutch master cylinder reservoir (Fig. (11) Disengage master cylinder hydraulic pipe from cowl retainer (Fig.
Page 227 2001 PT CRUISER 6a - 4 CLUTCH REMOVAL AND INSTALLATION (Continued) (3) Install hydraulic pipe into cowl retainer (Fig. (10) Install lower instrument panel bezel (Fig. 1). (11) Connect battery negative cable. (4) Install clutch master cylinder reservoir (Fig. 8). (12) Install air cleaner assembly (Fig.
Page 228 COOLING SYSTEM 7 - 1 COOLING SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION COOLANT LEVEL—SERVICING ... . . 20 COOLING SYSTEM ......1 COOLING SYSTEM—DRAINING.
Page 229 7 - 2 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar Antifreeze/Coolant, Year/100,000 Mile Formula (orange in color), or the equivalent ethylene glycol base coolant with corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended.
Page 230 COOLING SYSTEM 7 - 3 DESCRIPTION AND OPERATION (Continued) Fig. 2 Cooling System Operation OPERATION The system works in conjunction with the cooling system pressure cap to utilize thermal expansion and contraction of the coolant to keep the coolant free of trapped air.
Page 231 7 - 4 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 5 Thermostat 1 – AIR BLEED 2 – SEAL 3 – RETURN SPRING Fig. 4 Thermostat and Coolant Outlet Connector 4 – PELLET CHAMBER 1 – TIMING BELT COVER 2 – OUTLET CONNECTOR as well as sufficient heat transfer capabilities to keep 3 –...
Page 232 COOLING SYSTEM 7 - 5 DESCRIPTION AND OPERATION (Continued) Fig. 7 Power Distribution Center (PDC) 1 – PCM 2 – PDC Fig. 6 Radiator Fan RADIATOR FAN OPERATION CHART 1 – RADIATOR FAN 2 – SCREWS 3 – SCREWS Radiator Fan Control Low Speed High Speed ature of the coolant, which is sensed by the coolant...
Page 233 7 - 6 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) HOSE CLAMPS DESCRIPTION The cooling system utilizes both worm drive and spring type hose clamps. If a spring type clamp replacement is necessary, replace with the original Mopar equipment spring type clamp. CAUTION: A number or letter is stamped into the tongue of constant tension clamps.
Page 234 COOLING SYSTEM 7 - 7 DESCRIPTION AND OPERATION (Continued) OPERATION The water pump is the heart of the cooling system, pumping the coolant through the engine block, cylin- der head, heater system, hoses, and radiator. Fig. 11 Automatic Transmission Oil Cooler ACCESSORY DRIVE BELTS DESCRIPTION The accessory drive consist of two Poly-V type...
Page 235 7 - 8 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) ENGINE BLOCK HEATER DESCRIPTION The heater is mounted in a core hole (in place of a core hole plug) in the engine block, with the heating element immersed in coolant (Fig. 13). The engine block heater is available as an optional accessory.
Page 236 COOLING SYSTEM 7 - 9 DIAGNOSIS AND TESTING COOLING SYSTEM CONDITION POSSIBLE CAUSE CORRECTION TEMPERATURE GAUGE READS 1. Has a Diagnostic Trouble Code 1. Refer to On Board Diagnostic in (DTC) been set indicating a stuck EMISSION CONTROL SYSTEMS. open engine thermostat? Replace thermostat, if necessary.
Page 237 7 - 10 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION 6. Poor seals at pressure cap. 6. (a) Check condition of cap and cap seals. Refer to pressure cap inspection. Replace cap if necessary. (b) Check condition of filler neck. If neck is bent or damaged, replace neck.
Page 238 COOLING SYSTEM 7 - 11 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION 16. Thermostat partially or 16. Check thermostat operation and completely closed. replace as necessary. Refer to thermostat in this section for procedure. 17. Cooling fan not operating 17.
Page 239 7 - 12 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION 9. Loose drive belt (water pump 9. Check drive belt and correct as slipping). necessary. 10. Air leak on the suction side of 10. Locate leak and repair as water pump allows air to build up in necessary.
Page 240 COOLING SYSTEM 7 - 13 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION RADIATOR FAN OPERATES ALL 1. Malfunctioning electrical 1. Refer to appropriate Powertrain THE TIME component or circuit. Diagnostic Procedures. Repair as necessary. 2. Check for low coolant level. 2.
Page 241 7 - 14 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION INADEQUATE HEATER 1. Has a diagnostic trouble code 1. Refer to Powertrain Diagnostic PERFORMANCE (DTC) been set? Procedures. 2. Coolant level low. 2. Refer to testing cooling system for leaks in this section.
Page 242 COOLING SYSTEM 7 - 15 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION POOR DRIVEABILITY 1. Has a diagnostic trouble code 1. Refer to the Powertrain (THERMOSTAT POSSIBLY STUCK (DTC ) been set? Diagnostic Procedure manual for OPEN). GAUGE MAY BE READING checking a DTC related to the thermostat.
Page 243 7 - 16 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) ACCESSORY DRIVE BELTS CONDITION POSSIBLE CAUSE CORRECTION BELT SLIPPAGE 1. Belt slipping because of 1. Retension generator belt. insufficient tension. Replace the power steering belt’s automatic belt tensioner. 2. Belt excessively glazed or 2.
Page 244 COOLING SYSTEM 7 - 17 DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM FLOW CHECK CAP. PLACE A SHOP TOWEL OVER THE CAP, AND WITHOUT PUSHING DOWN, ROTATE IT COUNTER- To determine if coolant is properly flowing through CLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS the cooling system, use the following procedures: TO ESCAPE THROUGH THE OVERFLOW TUBE.
Page 245 7 - 18 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) If the needle on the dial does not fluctuate, race the engine a few times. If an abnormal amount of coolant or steam is emitted from the tail pipe, it may indicate a faulty head gasket, cracked engine block, or cracked cylinder head.
Page 246 COOLING SYSTEM 7 - 19 DIAGNOSIS AND TESTING (Continued) CAUTION: The radiator pressure tester is very sen- ENGINE BLOCK HEATER sitive to small air leaks that will not cause cooling If heater unit does not operate (Fig. 19), possible system problems. A pressure cap that does not causes can be either the power cord or the heater ele- have a history of coolant loss should not be ment.
Page 247 7 - 20 COOLING SYSTEM SERVICE PROCEDURES COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C (-34°F) to -59°C (-50°F).
Page 248 COOLING SYSTEM 7 - 21 SERVICE PROCEDURES (Continued) Fig. 22 Coolant Recovery Bottle and Pressure Cap 1 – ENGINE OIL FILL 3 – ENGINE OIL DIPSTICK 2 – COOLANT RECOVERY BOTTLE 4 – COOLANT PRESSURE CAP (2) Without removing the pressure cap and with COOLING SYSTEM—FILLING system not under pressure, turn draincock counter- clockwise to open (Fig.
Page 249 7 - 22 COOLING SYSTEM SERVICE PROCEDURES (Continued) (4) Remove water pump attaching screws to engine and remove pump (Fig. 25). Fig. 24 Cooling System Bleed Valve NOTE: Be careful not to spill coolant on drive belts or the generator. (5) Slowly continue filling until a steady stream of coolant flows from the attached hose on the bleed Fig.
Page 250 COOLING SYSTEM 7 - 23 REMOVAL AND INSTALLATION (Continued) Fig. 27 Water Pump Inlet Tube Fasteners 1 – BOLTS 2 – HOSE - HEATER RETURN Fig. 26 Water Pump Body 3 – WATER PUMP INLET TUBE 1 – IMPELLER 2 – WATER PUMP BODY 3 –...
Page 251 7 - 24 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) (4) Remove coolant recovery system hose from out- let connector. (5) Remove thermostat/coolant outlet connector bolts (Fig. 29). (6) Remove thermostat assembly, and clean sealing surfaces. Fig. 30 Thermostat Position 1 – LOCATOR NOTCH 2 –...
Page 252 COOLING SYSTEM 7 - 25 REMOVAL AND INSTALLATION (Continued) (13) Remove the cooling module assembly (radia- tor, fan and A/C condenser) (Fig. 33) by lifting it up from the engine compartment. Care should be taken not to damage the cooling fins and tubes during removal.
Page 253 7 - 26 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 33 Cooling Module Assembly Fig. 35 Air Seals 1 – UPPER RADIATOR CROSSMEMBER 1 – A/C CONDENSER 2 – COOLING MODULE 2 – SIDE AIR SEALS 3 – RADIATOR FAN CONNECTOR 3 –...
Page 254 COOLING SYSTEM 7 - 27 REMOVAL AND INSTALLATION (Continued) (3) Turn the draincock back (clockwise) 1/8 turn. (7) Hoist vehicle. (4) Pull the draincock (Fig. 36) from the radiator (8) Disconnect radiator fan electrical connector. tank. (9) Remove the two lower and left side radiator fan screws (Fig.
Page 255 7 - 28 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) AUTOMATIC TRANSMISSION OIL COOLER COOLANT RECOVERY BOTTLE REMOVAL REMOVAL (1) Remove front fascia. Refer to BODY for proce- (1) Disconnect recovery hose from coolant outlet dure. connector (Fig. 40). (2) Disconnect hoses from oil cooler (Fig. 38). (2) Disconnect the MAP sensor connector.
Page 256 COOLING SYSTEM 7 - 29 REMOVAL AND INSTALLATION (Continued) Fig. 42 Engine Block Heater 1 – BLOCK HEATER 2 – POWER CORD Fig. 41 Coolant Recovery Bottle 1 – COOLANT RECOVERY CONTAINER 2 – SCREW 3 – NUT INSTALLATION (1) Install coolant recovery bottle and tighten fas- teners to 4 N·m (35 in.
Page 257 7 - 30 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) ACCESSORY DRIVE BELTS POWER STEERING PUMP AND AIR CONDITIONING COMPRESSOR BELT REMOVAL (1) Remove belt splash shield (Fig. 44). (2) Using a wrench, rotate belt tensioner clockwise (Fig. 45) until belt can be removed from power steer- ing pump pulley.
Page 258 COOLING SYSTEM 7 - 31 REMOVAL AND INSTALLATION (Continued) Fig. 46 Power Steering/Air Conditioning Belt 1 – P/S PULLEY 5 – BELT 2 – P/S PULLEY 6 – IDLER PULLEY 3 – A/C PULLEY 7 – CRANKSHAFT PULLEY 4 – CRANKSHAFT PULLEY 8 –...
Page 259 7 - 32 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) (a) Connect 8371 to the DRBIII following the REMOVAL instructions provided in tool kit. (1) Remove power steering/air conditioning belt. (b) Place end of microphone probe approximately Refer to procedure in this section. 2.54 cm (1 in.) from belt at one of the belt center (2) Remove tensioner mounting bolt and remove span locations shown in (Fig.
Page 260 COOLING SYSTEM 7 - 33 CLEANING AND INSPECTION (Continued) ACCESSORY DRIVE BELTS A replacement cap must be of the type designed for coolant reserve systems. This design ensures system pressurization. CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and cool- ants before installing the drive belt.
Page 261 7 - 34 COOLING SYSTEM CLEANING AND INSPECTION (Continued) INSPECTION SPECIFICATIONS After performing a flush procedure, inspect all COOLANT PERFORMANCE hoses, clamps and connections for deterioration and leaks. Inspect radiator and heater core for leaks. Coolant performance is measurable. For heat transfer, pure water absorbs 1 btu for each degree of RADIATOR temperature rise for each pound of water.
Page 262 COOLING SYSTEM 7 - 35 SPECIFICATIONS (Continued) COOLING SYSTEM CAPACITY SPECIAL TOOLS 7.0 Liters* (7.4 qts.)* COOLING SYSTEM *Capacity includes Heater and Coolant Reserve System. TORQUE SPECIFICATIONS DESCRIPTION N·m Lbs. Lbs. A/C Condenser to Radiator— — Screws Cooling System Tester – 7700 Automatic Belt Tensioner —...
Page 264 2001 PT CRUISER COOLING SYSTEM 7a - 1 COOLING SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION SPECIFICATIONS ACCESSORY DRIVE BELTS ....1 TORQUE SPECIFICATIONS .
Page 265 2001 PT CRUISER 7a - 2 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 3 Generator Belt 1 – ADJUSTING BOLT 2 – LOCKING NUT 3 – PIVOT BOLT (b) Place end of microphone probe approximately 2.54 cm (1 in.) from belt at one of the belt center span locations shown in (Fig.
Page 266 2001 PT CRUISER COOLING SYSTEM 7a - 3 REMOVAL AND INSTALLATION (Continued) BELT TENSION CHART SPECIAL TOOLS COOLING SYSTEM Accessory Belt Tension Drive Belt Power Steering Pump and A/C Dynamic Tensioner Compressor New 135 lb. 158-162 Hz Generator Used 100 lb. 127-133 Hz SPECIFICATIONS Belt Tension Gauge Adapter –...
Page 267 2001 PT CRUISER...
Page 268 BATTERY 8A - 1 BATTERY TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION BATTERY....... . 1 BATTERY.
Page 269 8A - 2 BATTERY DESCRIPTION AND OPERATION (Continued) be cleaned when other under hood maintenance is performed. When the electrolyte level is below the top of the plates, Clear in the test Indicator, the battery must be replaced. The battery must be completely charged, and the battery top, posts, and cable clamps must be cleaned before diagnostic procedures are performed.
Page 270 BATTERY 8A - 3 DIAGNOSIS AND TESTING (Continued) CAUSES OF BATTERY DISCHARGING ignition OFF to function properly. When a vehicle is not used over an extended period of approximately 20 It is normal to have a small 5 to 25 milliamperes days the IOD fuse should be pulled.
Page 271 8A - 4 BATTERY DIAGNOSIS AND TESTING (Continued) ABNORMAL BATTERY DISCHARGING The following should be checked for and verified: • Corroded battery posts, cables or terminals. • Loose or worn generator drive belt. • Electrical loads that exceed the output of the charging system due to equipment or accessories installed after delivery.
Page 272 BATTERY 8A - 5 DIAGNOSIS AND TESTING (Continued) (3) Allow the battery to stabilize for 2 minutes, and then verify the open circuit voltage (Fig. 7). (4) This voltage reading will approximate the state of charge of the battery. It will not reveal battery cranking capacity.
Page 273 8A - 6 BATTERY SERVICE PROCEDURES (Continued) WARNING: DO NOT CHARGE A BATTERY THAT BATTERY CHARGING TIME REQUIRED HAS EXCESSIVELY LOW ELECTROLYTE LEVEL. BATTERY SPARK INTERNALLY WARNING: NEVER EXCEED AMPS WHEN EXPLODE. EXPLOSIVE GASES FORM OVER THE CHARGING A COLD -1°C (30°F) BATTERY. PER- BATTERY.
Page 274 BATTERY 8A - 7 SERVICE PROCEDURES (Continued) STATE OF CHARGE A completely discharged battery requires more charging time than a partially charged battery. Elec- trolyte is nearly pure water in a completely dis- charged battery. At first, the charging current amperage will be low.
Page 275 8A - 8 BATTERY REMOVAL AND INSTALLATION (Continued) BATTERY CABLES NEGATIVE BATTERY CABLE REMOVAL (1) Open hood. (2) Remove Battery. Refer to Removal and Instal- lation, Battery in this section. (3) Remove Battery Tray. Refer to Removal and Installation, Battery Tray in this section. (4) Remove one nut retaining ground strap to left inner fender (Fig.
Page 276 BATTERY 8A - 9 REMOVAL AND INSTALLATION (Continued) POSITIVE BATTERY CABLE (2) Open hood. (3) Remove Air Cleaner Box. Refer to Fuel Deliv- REMOVAL ery, Air Cleaner Box Removal and Installation. (4) Disconnect and isolate the battery negative (1) Set vehicle on hoist. cable.
Page 277 8A - 10 BATTERY REMOVAL AND INSTALLATION (Continued) BATTERY TRAY REMOVAL (1) Open hood. (2) Remove the battery. Refer to Battery Removal and Installation in this section. (3) Remove six bolts retaining the battery tray. (4) Lift the battery tray out of the engine compart- ment and remove from the vehicle.
Page 278 BATTERY 8A - 11 SPECIFICATIONS (Continued) Fig. 16 Cleaning Battery Cable Terminal - Typical 1 – BATTERY CABLE CLEANER 2 – BATTERY CABLE 3 – TEST INDICATOR Fig. 14 Cleaning Battery - Typical 1 – BATTERY SPECIFICATIONS 2 – CLEANING BRUSH 3 –...
Page 280 STARTING SYSTEMS 8B - 1 STARTING SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION STARTING SYSTEM ..... . . 5 STARTING SYSTEM .
Page 281 8B - 2 STARTING SYSTEMS DESCRIPTION AND OPERATION (Continued) • To disable the ignition and fuel systems, discon- OPERATION nect the Automatic Shutdown Relay (ASD). The ASD As battery power is applied to the relay from the relay is located in the in the Power Distribution Cen- ignition switch, battery power is applied to the ter (PDC).
Page 282 STARTING SYSTEMS 8B - 3 DIAGNOSIS AND TESTING (Continued) no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. (2) Resistance between terminals 85 and 86 (elec- tromagnet) should be 75 5 ohms.
Page 283 8B - 4 STARTING SYSTEMS DIAGNOSIS AND TESTING (Continued) BATTERY still above 0.2 volt after correcting poor contacts, replace battery positive cable. Refer to Battery for Diagnosis and Testing of the (b) If resistance tests do not detect feed circuit battery.
Page 284 STARTING SYSTEMS 8B - 5 DIAGNOSIS AND TESTING (Continued) ASD relay is located in the Power Distribution Cen- INSPECTION ter (PDC). Refer to the PDC cover for proper relay Before removing any unit from the starting system location. for repair or diagnosis, perform the following inspec- (3) Verify that all lights and accessories are OFF, tions: •...
Page 285 8B - 6 STARTING SYSTEMS DIAGNOSIS AND TESTING (Continued) STARTING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION STARTER FAILS 1. BATTERY 1. REFER TO BATTERY. CHARGE OR REPLACE BATTERY, IF TO ENGAGE. DISCHARGED OR REQUIRED. FAULTY. 2. REFER TO FEED CIRCUIT RESISTANCE TEST AND FEED 2.
Page 286 STARTING SYSTEMS 8B - 7 REMOVAL AND INSTALLATION SAFETY SWITCHES For Removal and Installation of the: • Clutch Interlock/Upstop Switch, refer to Clutch, Removal and Installation. • Park/Neutral Starting Back-Up Lamp Switch, refer to Transaxle, Removal and Installation. STARTER MOTOR REMOVAL (1) Open Hood.
Page 287 8B - 8 STARTING SYSTEMS NOTE: Engine should be up to operating tempera- SPECIFICATIONS ture. Extremely heavy oil or tight engine will increase starter amperage draw. STARTER MOTOR ENGINE APPLICATION 2.4L DOHC TORQUE POWER RATING 1.2 KW VOLTAGE 12 VOLTS DESCRIPTION TORQUE NUMBER OF FIELDS...
Page 288 CHARGING SYSTEM 8C - 1 CHARGING SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION CHARGING SYSTEM..... . . 1 GENERATOR-2.4 L .
Page 289 8C - 2 CHARGING SYSTEM DESCRIPTION AND OPERATION (Continued) The IAT Sensor is a Negative Temperature Coeffi- ELECTRONIC VOLTAGE REGULATOR cient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering DESCRIPTION the intake manifold. The Electronic Voltage Regulator (EVR) is not a separate component.
Page 290 CHARGING SYSTEM 8C - 3 DESCRIPTION AND OPERATION (Continued) A DTC does not identify which component in a cir- cuit is bad. Thus, a DTC should be treated as a symptom, not as the cause for the problem. In some cases, because of the design of the diagnostic test procedure, a DTC can be the reason for another DTC to be set.
Page 291 8C - 4 CHARGING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 5 Lower Pivot Bolt Fig. 7 Generator Removal 1 – LOWER PIVOT BOLT (2) Install the generator belt, refer to the Cooling section for more information. (3) Install axle shaft, refer to the Axle section (4) Install lower control arm to steering knuckle, refer to the Supension section.
Page 292 CHARGING SYSTEM 8C - 5 SPECIFICATIONS GENERATOR RATINGS TYPE ENGINES MINIMUM TEST AMPS MELCO 2.4L 120 amps The Test Specifications are: 1. 2500 20 RPM 2. Voltage Output 15V 3. Field Current 5amps .1amp TORQUE DESCRIPTION TORQUE Battery Terminal Nut ..10 N·m (90 in. lbs.) Battery Hold Down Clamp Bolt .
Page 294 IGNITION SYSTEM 8D - 1 IGNITION SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION AUTOMATIC SHUTDOWN RELAY... . . 7 IGNITION SYSTEM ......1 CAMSHAFT POSITION SENSOR.
Page 295 8D - 2 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) between the electrodes (Fig. 2) to the dimensions resistance. To maintain proper sealing at the ter- specified in the chart at the end of this section by minal connections, the connections should not bending the ground electrode (just above the attach- be broken unless testing indicates high resis- ment weld) with the appropriate tool.
Page 296 IGNITION SYSTEM 8D - 3 DESCRIPTION AND OPERATION (Continued) AUTOMATIC SHUTDOWN RELAY CRANKSHAFT POSITION SENSOR—2.4L DESCRIPTION DESCRIPTION The ASD relay is located in the PDC (Fig. 4). The The crankshaft position sensor mounts to the inside top of the PDC cover has a label showing relay engine block below the generator and near the oil fil- and fuse identification.
Page 297 8D - 4 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 6 Timing Reference Notches —Typical 1 – MACHINED NOTCHES 2 – CRANKSHAFT POSITION SENSOR The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts).
Page 298 IGNITION SYSTEM 8D - 5 DESCRIPTION AND OPERATION (Continued) KNOCK SENSOR DESCRIPTION The knock sensor threads into the cylinder block. The knock sensor is designed to detect engine vibra- tion that is caused by detonation. OPERATION When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM.
Page 299 8D - 6 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) IGNITION SWITCH REMOVAL AND INSTALLATION In the RUN position, the ignition switch connects SPARK PLUG CABLES—2.4L power from the Power Distribution Center (PDC) to a fuse in the fuse block, back to a bus bar in the PDC. Clean high tension cables with a cloth moistened The bus bar feeds circuits for the Powertrain Control with a non-flammable solvent.
Page 300 IGNITION SYSTEM 8D - 7 REMOVAL AND INSTALLATION (Continued) NOTE: REMOVE cables from coil first before INSTALLATION removing spark plug insulator. (1) Install coil pack on valve cover. Tighten the bolts to 11.8 N·m (105 20 in. lbs.). Special care should be used when installing spark (2) Transfer spark plug cables to new coil pack.
Page 301 8D - 8 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) CAMSHAFT POSITION SENSOR The camshaft position sensor is mounted to the rear of the cylinder head (Fig. 14). Fig. 15 Target Magnet Removal/Installation 1 – CAM MAGNET/TARGET Fig. 14 Camshaft Position Sensor Location—DOHC 2 –...
Page 302 IGNITION SYSTEM 8D - 9 REMOVAL AND INSTALLATION (Continued) (4) Disconnect electrical connector from crankshaft position sensor. (5) Remove sensor mounting screw. Remove sensor. INSTALLATION (1) Install sensor and tighten the screw to 13 N·m (115 15 in. lbs.). (2) Connect electrical connector to crankshaft posi- tion sensor.
Page 303 8D - 10 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 20 Steering Column Shrouds 1 – SCREW ACCESS HOLE 2 – TAB ACCESS HOLE Fig. 22 Multi-Function Switch 3 – LOWER SHROUD (4) Remove upper and lower shrouds from steering column.
Page 304 IGNITION SYSTEM 8D - 11 REMOVAL AND INSTALLATION (Continued) Fig. 26 Ignition Lock Cylinder Detentes REMOVAL (1) Disconnect negative cable from battery. Fig. 24 Removing Ignition Switch (2) Place key cylinder in RUN position. Through the hole in the lower shroud, depress lock cylinder retaining tab and remove key cylinder.
Page 305 VEHICLE EMISSION CONTROL INFORMATION LABEL DESCRIPTION All models have a Vehicle Emission Control Infor- mation (VECI) Label. Chrysler permanently attaches 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- FIRING ORDER—2.4L...
Page 306 IGNITION SYSTEM 8D - 13 SPECIFICATIONS (Continued) IGNITION COILS Primary Resistance at Secondary Resistance at 21°C-27°C Engines Coil Manufacture 21°C-27°C (70°F-80°F) (70°F-80°F) Toyodenso/ 2.4L 0.51 TO 0.61 Ohms 11,500 to 13,500 Ohms Diamond Coil Polarity Coil Polarity...
Page 308 INSTRUMENT PANEL SYSTEMS 8E - 1 INSTRUMENT PANEL SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION CENTER CONSOLE FLOOD LAMP ... . 7 INSTRUMENT PANEL ASSEMBLY ... . 1 CLUSTER AREA SUPPORT PANEL.
Page 309 8E - 2 INSTRUMENT PANEL SYSTEMS DESCRIPTION AND OPERATION (Continued) Fig. 1 Instrument Panel Assembly 1 – LEFT I/P A/C OUTLET HOUSING 9 – RIGHT I/P ENDCAP 2 – INSTRUMENT CLUSTER 10 – I/P GLOVE BOX ASSEMBLY 3 – INSTRUMENT CLUSTER BEZEL 11 –...
Page 310 INSTRUMENT PANEL SYSTEMS 8E - 3 DESCRIPTION AND OPERATION (Continued) Fig. 2 Instrument Cluster • Malfunction Indicator Lamp (MIL) (service BRAKE SYSTEM WARNING LAMP TEST engine soon) The brake warning lamp illuminates when the • Seat Belt Warning parking brake is applied with the ignition switch •...
Page 311 8E - 4 INSTRUMENT PANEL SYSTEMS DIAGNOSIS AND TESTING (Continued) indicator, turn signal indicators, and gauge illumina- 26-WAY CLUSTER HARNESS CONNECTOR PIN tion bulbs. Non of these though will illuminate, along CALL-OUT with the security indicator, during the bulb check at initial KEY ON.
Page 312 INSTRUMENT PANEL SYSTEMS 8E - 5 SERVICE PROCEDURES (Continued) 10-WAY CLUSTER HARNESS CONNECTOR PIN CALL-OUT CAV. FUNCTION FRONT FOG VEHICLE THEFT/SECURITY SYSTEM (VTSS) SPARE INPUT 5 SPARE INPUT 4 SPARE INPUT 3 REAR FOG PANEL DIMMING LEVEL SPARE INPUT 1 FUEL SENSOR SPARE INPUT 2 NOTE: If a vehicle/instrument cluster is received...
Page 313 8E - 6 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) (3) Remove the instrument panel center bezel. Refer to Removal and Installation, Instrument Panel Center Bezel in this section. (4) Remove two screws retaining the accessory switch bezel (Fig. 5). Fig.
Page 314 INSTRUMENT PANEL SYSTEMS 8E - 7 REMOVAL AND INSTALLATION (Continued) INSTALLATION CENTER CONSOLE FLOOD LAMP (1) Install the three retaining screws to the cluster REMOVAL bezel mounted a/c outlet housing. (2) Place the cluster bezel near the instrument (1) Open hood. cluster and insert the turn signal lamps into the (2) Disconnect and isolate the battery negative instrument cluster bezel (Fig.
Page 315 8E - 8 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Insert new bulb. (2) Gently secure bulb back into slot. NOTE: When installing the retainer, ensure that the forward tabs are inserted properly into the slots in the instrument panel. (3) Connect the battery negative cable (Fig.
Page 316 INSTRUMENT PANEL SYSTEMS 8E - 9 REMOVAL AND INSTALLATION (Continued) Fig. 12 Glove Box Assembly Breakdown 1 – LATCH 2 – INNER DOOR 3 – OUTER DOOR 4 – BOX Fig. 10 Glove Box Assembly Hinge INSTALLATION GLOVE BOX DOOR/BIN/LATCH (1) Reassemble glove box assembly (Fig.
Page 317 8E - 10 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Place the HVAC control in the instrument panel opening. (2) Connect two control cables. (3) Connect the vacuum harness connector. (4) Connect the one wiring connector. (5) Install the two screws retaining the HVAC con- trol head.
Page 318 INSTRUMENT PANEL SYSTEMS 8E - 11 REMOVAL AND INSTALLATION (Continued) INSTRUMENT CLUSTER/MASK and LENS CAUTION: DO NOT turn cluster upside down for longer than 30 minutes (preferably NEVER). This can result in dampening fluid within the gauge pointer assembly to leak causing permanent dam- age to the instrument cluster gauges.
Page 319 8E - 12 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 19 Instrument Cluster Bezel Remove/Install Fig. 20 Turn Signal Indicator Lamps Remove/Install (6) Install the instrument panel top cover. Refer to Removal and Installation, Instrument Panel Top Cover in this section. (7) Connect the battery negative cable (Fig.
Page 320 INSTRUMENT PANEL SYSTEMS 8E - 13 REMOVAL AND INSTALLATION (Continued) (7) Gently pry the upper and lower shrouds apart and remove from steering column. (8) Remove the left lower instrument panel bezel. Pull top rearward, lower to floor and with a quick pulling motion remove off instrument panel.
Page 321 8E - 14 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 24 Instrument Panel Assembly...
Page 322 INSTRUMENT PANEL SYSTEMS 8E - 15 REMOVAL AND INSTALLATION (Continued) 1 – COVER, INSTRUMENT PANEL TOP 10 – BEZEL, INSTRUMENT PANEL LOWER 2 – ASSEMBLY, INSTRUMENT PANEL 11 – KNOBS, A/C CONTROL ASSEMBLY 3 – HOUSING, INSTRUMENT PANEL OUTBOARD A/C OUTLET 12 –...
Page 323 8E - 16 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) (27) Remove two screws to the right instrument panel end cap. (28) Pull end cap rearward to unsnap and remove from vehicle. (29) Remove the two right side A-pillar, instru- ment panel retaining bolts and one nut (Fig.
Page 324 INSTRUMENT PANEL SYSTEMS 8E - 17 REMOVAL AND INSTALLATION (Continued) Fig. 28 Instrument Panel Fence Line Retaining Bolts INSTALLATION (6) Install two screws to the right instrument panel end cap. (1) With the help of an assistant, carefully install (7) Install glove box assembly: the instrument panel in the vehicle being careful not (a) Place glove box assembly in position and to damage the instrument panel or vehicle interior.
Page 325 8E - 18 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) (9) Connect the following two center console wiring (28) Place HVAC control head into place in instru- connectors: ment panel. (a) Occupant Restraint Controller (ORC) connec- (29) Connect the following onto the HVAC control head: (b) Park Brake Switch connector (a) Two control cables...
Page 326 INSTRUMENT PANEL SYSTEMS 8E - 19 REMOVAL AND INSTALLATION (Continued) (5) Reconnect the battery negative cable (Fig. 4). (6) Close hood. (7) Verify operation of vehicle and systems. INSTRUMENT PANEL END CAP LEFT END CAP REMOVAL (1) Remove the left lower instrument panel bezel. Pull top rearward, lower to floor and with a quick pulling motion remove off instrument panel.
Page 327 8E - 20 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) (4) Place left lower instrument panel bezel in posi- (7) Using a trim stick or equivalent, gently pry off tion and make sure the orientation of the hinge is the center bezel and remove (Fig. 31). correct and snap bezel hinge into place (8) Remove the two top cover retaining screws (5) Roll bezel upward and snap into place.
Page 328 INSTRUMENT PANEL SYSTEMS 8E - 21 REMOVAL AND INSTALLATION (Continued) Fig. 34 Instrument Panel Top Cover Remove/Install...
Page 329 8E - 22 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) LEFT LOWER INSTRUMENT PANEL BEZEL REMOVAL (1) Pull the top of the left lower instrument panel bezel rearward. (2) Swing top of left lower instrument panel bezel to floor. (3) With a quick pulling motion remove off instru- ment panel (Fig.
Page 330 INSTRUMENT PANEL SYSTEMS 8E - 23 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Connect the upper and lower steering column shrouds (Fig. 37). NOTE: Ensure that the locking tabs on the inboard and outboard sides of the shrouds are secure. (2) Install column shroud retaining...
Page 332 2001 PT CRUISER INSTRUMENT PANEL AND SYSTEMS 8Ea - 1 INSTRUMENT PANEL AND SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION HEADLAMP LEVELING SYSTEM ... . . 1 INSTRUMENT PANEL - RHD .
Page 333 2001 PT CRUISER 8Ea - 2 INSTRUMENT PANEL AND SYSTEMS DESCRIPTION AND OPERATION (Continued) • DO NOT SWAP INSTRUMENT CLUSTERS INSTRUMENT CLUSTER BETWEEN TWO VEHICLES WHEN TRYING TO DIAGNOSE A POSSIBLE FAULTY CLUSTER. DESCRIPTION DIAGNOSIS AND TESTING HEADLAMP LEVELING SWITCH The following test is designed to diagnose a possi- ble faulty headlamp leveling switch.
Page 334 2001 PT CRUISER INSTRUMENT PANEL AND SYSTEMS 8Ea - 3 DIAGNOSIS AND TESTING (Continued) HEADLAMP LEVELING SWITCH SWITCH POSITION RESISTANCE BETWEEN PINS 1&2 0.752 0.564 348.8 249.2 REMOVAL AND INSTALLATION INSTRUMENT PANEL - RHD Fig. 5 Headlamp Leveling Switch Location 1 –...
Page 335 2001 PT CRUISER 8Ea - 4 INSTRUMENT PANEL AND SYSTEMS REMOVAL AND INSTALLATION (Continued) (2) Verify switch, headlamp leveling system opera- tion. (3) Install the headlamp leveling switch in the accessory switch bezel. (4) Position and install the accessory switch bezel retaining screws (Fig.
Page 336 AUDIO SYSTEM 8F - 1 AUDIO SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION AUDIO SYSTEM ......1 D-PILLAR SPEAKER .
Page 337 8F - 2 AUDIO SYSTEM DIAGNOSIS AND TESTING (Continued) Fig. 1 Interference Elimination Ground Strap Location IN-CAR ANTENNA TESTING (2) No continuity should be observed or a very high resistance of several megohms between the The antenna has a short cable which connects into ground shell of the connector and radio end pin.
Page 338 AUDIO SYSTEM 8F - 3 DIAGNOSIS AND TESTING (Continued) AM/FM STEREO - CD - CASSETTE TAPE...
Page 339 8F - 4 AUDIO SYSTEM DIAGNOSIS AND TESTING (Continued) AM/FM STEREO CONTINUED...
Page 340 AUDIO SYSTEM 8F - 5 DIAGNOSIS AND TESTING (Continued) AM/FM STEREO CONTINUED...
Page 341 8F - 6 AUDIO SYSTEM DIAGNOSIS AND TESTING (Continued) AM/FM STEREO CONTINUED...
Page 342 AUDIO SYSTEM 8F - 7 DIAGNOSIS AND TESTING (Continued) AM/FM STEREO CONTINUED...
Page 343 8F - 8 AUDIO SYSTEM DIAGNOSIS AND TESTING (Continued) REMOVAL AND INSTALLATION D-PILLAR SPEAKER REMOVAL (1) Disconnect and isolate the battery negative cable (Fig. 4). Fig. 2 Antenna Test Points - Typical 1 – TIP OF MAST TEST POINT 2 – DISCONNECT TEST POINTS 3 –...
Page 344 AUDIO SYSTEM 8F - 9 REMOVAL AND INSTALLATION (Continued) FRONT DOOR SPEAKER Fig. 6 Front Door Speaker Location 1 – DOOR TRIM PANEL 2 – DOOR SPEAKER Fig. 5 D-Pillar Speaker Remove/Install INSTALLATION REMOVAL (1) Place speaker into opening, connect wire connec- (1) Disconnect and isolate the battery negative tor and install four speaker retaining screws (Fig.
Page 345 8F - 10 AUDIO SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 7 Front Door Speaker Remove/Install INSTRUMENT PANEL SPEAKER REMOVAL (1) Disconnect and isolate the battery negative cable (Fig. 4). (2) Remove instrument panel top cover. Refer to Instrument Panel Systems, Instrument Panel Top Cover Removal and Installation.
Page 346 AUDIO SYSTEM 8F - 11 REMOVAL AND INSTALLATION (Continued) Fig. 9 Instrument Panel Speakers Remove/install...
Page 347 8F - 12 AUDIO SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 10 Mast and Antenna Assembly Remove/Install MAST and ANTENNA ASSEMBLY INSTALLATION (1) Align antenna adapter tongue with grove in REMOVAL the fender hole and push adapter into fender. (2) From under the fender, push the antenna base (1) Disconnect and isolate the battery negative and cable assembly through the adapter in the cable (Fig.
Page 348 AUDIO SYSTEM 8F - 13 REMOVAL AND INSTALLATION (Continued) RADIO NOTE: All factory-installed radios are readily identi- fiable by a three-digit alphabetical sales code, which is imprinted on the face plate lens, just below the Pentastar emblem. REMOVAL (1) Disconnect and isolate the battery negative cable (Fig.
Page 350 2001 PT CRUISER AUDIO SYSTEMS 8Fa - 1 AUDIO SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION ANTENNA MAST......4 MECHANICAL TELESCOPING ANTENNA .
Page 351 2001 PT CRUISER 8Fa - 2 AUDIO SYSTEMS REMOVAL AND INSTALLATION MECHANICAL TELESCOPING ANTENNA REMOVAL (1) Turn ignition key to the “off” position. Fig. 4 Antenna Lead Location - RHD shown (LHD symmetrically opposite) 1 – ANTENNA CABLE Fig. 3 Telescoping Antenna 1 –...
Page 352 2001 PT CRUISER AUDIO SYSTEMS 8Fa - 3 REMOVAL AND INSTALLATION (Continued) INSTALLATION (9) Remove antenna retaining nut (Fig. 6). (1) Position antenna assembly and push antenna lead through the hole in A-pillar. Install sealing grommet. (2) Install air blocker and wheel well trim retain- ing screws.
Page 353 2001 PT CRUISER 8Fa - 4 AUDIO SYSTEMS REMOVAL AND INSTALLATION (Continued) ANTENNA MAST REMOVAL (1) Turn ignition key to the “off” position. (2) Mask area around antenna with masking tape to prevent vehicle paint damage. (3) Remove antenna retaining nut shroud (Fig. 9). Fig.
Page 354 HORN SYSTEM 8G - 1 HORN SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION HORN SWITCH TEST ..... . 3 HORN SYSTEM.
Page 355 8G - 2 HORN SYSTEM DESCRIPTION AND OPERATION (Continued) The horn relay is located in the PDC. Refer to the HORN CONNECTOR PIN CALL-OUT PDC label for horn relay identification and location. If a problem is encountered with a continuously PIN # CIRCUIT NAME sounding horn, it can usually be quickly resolved by...
Page 356 HORN SYSTEM 8G - 3 DIAGNOSIS AND TESTING (Continued) (5) Check relay for 70 to 75 ohms resistance from (9) Depress the horn switch, and the meter should terminal 85 to 86 (Fig. 2). If resistance not OK, show continuity. If there is no continuity, replace the replace relay.
Page 357 8G - 4 HORN SYSTEM DIAGNOSIS AND TESTING (Continued) HORN SYSTEM TEST CONDITION POSSIBLE CAUSE CORRECTION HORN SOUNDS CONTINUOUSLY. (1) FAULTY HORN RELAY. (1) REFER TO HORN RELAY TEST IN NOTE: IMMEDIATELY UNPLUG HORN (2) HORN CONTROL CIRCUIT THIS SECTION. RELAY IN THE (PDC) TO RELAY SHORTED TO (2) CHECK TERMINAL 65 IN PDC FOR...
Page 358 HORN SYSTEM 8G - 5 INSTALLATION REMOVAL AND INSTALLATION (1) Install the two screws holding the horn assem- HORN bly to the vehicle (Fig. 6). (2) Connect the harness connector. REMOVAL (3) Install the left front wheelhouse splash shield. Refer to Body, Removal and Installation, Front (1) Open hood.
Page 359 8G - 6 HORN SYSTEM REMOVAL AND INSTALLATION (Continued) REMOVAL (6) Remove the four screws holding the airbag cov- er/horn switch to the airbag module (Fig. 8). (1) Open hood. (7) Release the four clips on the airbag cover/horn (2) Disconnect and isolate the battery negative switch to the airbag module (Fig.
Page 360 VEHICLE SPEED CONTROL SYSTEM 8H - 1 VEHICLE SPEED CONTROL SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION VEHICLE SPEED AND DISTANCE ... . . 5 SPEED CONTROL SYSTEM ....1 ROAD TEST .
Page 361 8H - 2 VEHICLE SPEED CONTROL SYSTEM DESCRIPTION AND OPERATION (Continued) in RAM for speed control. To store a set speed, The vacuum chamber contains a diaphragm with a depress the SET switch while the vehicle is moving cable attached to control the throttle linkage. at a speed between 25 and 85 mph.
Page 362 VEHICLE SPEED CONTROL SYSTEM 8H - 3 DESCRIPTION AND OPERATION (Continued) the system voltage between turning the speed control DOWNSHIFT DELAY system on (for the first press) and off (for the second press). The Word Cruise will then illuminate on the DESCRIPTION cluster.
Page 363 8H - 4 VEHICLE SPEED CONTROL SYSTEM DESCRIPTION AND OPERATION (Continued) AUTOMATIC SPEED CONTROL OVERSPEED When the brakes are applied, the contacts open, causing the PCM’s output brake signal to go high, REDUCTION disengaging the speed control, cutting off PCM power to the speed control solenoids.
Page 364 VEHICLE SPEED CONTROL SYSTEM 8H - 5 DESCRIPTION AND OPERATION (Continued) VACUUM RESERVOIR trol set speed. Refer to the appropriate Powertrain Diagnostic Procedures manual for diagnosis and test- ing of this component. DESCRIPTION The vacuum reservoir is located in the right front ROAD TEST fender well on the frame rail (Fig.
Page 365 8H - 6 VEHICLE SPEED CONTROL SYSTEM DESCRIPTION AND OPERATION (Continued) A speed control malfunction may occur without a diagnostic code being indicated. For further information and usage of the DRB scan tool and a more complete list of Diagnostic Trouble Code and No Trouble Codes, refer to the Powertrain Diagnostic Manual.
Page 366 VEHICLE SPEED CONTROL SYSTEM 8H - 7 REMOVAL AND INSTALLATION (Continued) REMOVAL INSTALLATION (1) Remove the air cleaner lid, disconnect the inlet (1) Connect the electrical connector. air temperature sensor and makeup air hose. (2) Install switch (Fig. 8) and tighten the screws to (2) Remove the negative battery cable.
Page 367 8H - 8 VEHICLE SPEED CONTROL SYSTEM REMOVAL AND INSTALLATION (Continued) (8) Remove throttle cable clasp from the throttle INSTALLATION body cam (Fig. 10). (1) Install cable core wire through center hole on bracket, onto servo center post. (2) Install retaining clip to cable at servo (Fig. 9). (3) Slide cable bell housing over servo mounting studs through the bracket.
Page 368 VEHICLE SPEED CONTROL SYSTEM 8H - 9 REMOVAL AND INSTALLATION (Continued) REMOVAL (1) Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose. (2) Remove the negative battery cable. (3) Raise vehicle and support. (4) Remove the right front wheel. (5) Remove the front half of the inner splash shield and relocate rearward (Fig.
Page 370 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 1 TURN SIGNAL AND HAZARD WARNING SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION DIAGNOSIS AND TESTING TURN SIGNAL SYSTEM ....1 MULTI-FUNCTION SWITCH .
Page 371 8J - 2 TURN SIGNAL AND HAZARD WARNING SYSTEMS DESCRIPTION AND OPERATION (Continued) OPERATION HEADLAMP SWITCH When the driver wishes to signal his intentions to DESCRIPTION change direction of travel, he moves the lever upward to cause the right signals to flash and downward to The headlamp switch is integral to the left stalk of cause the left signals to flash.
Page 372 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 3 DESCRIPTION AND OPERATION (Continued) not become active until it is provided a signal ground inputs are provided to the flasher through the multi- from the turn signal switch or hazard warning function switch on the steering column.
Page 373 8J - 4 TURN SIGNAL AND HAZARD WARNING SYSTEMS DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION SYSTEM DOES NOT FLASH ON (1) FAULTY FUSE. (1) REPLACE FUSE. EITHER SIDE. (2) FAULTY FLASHER UNIT. (2) REPLACE FLASHER. (3) LOOSE BULKHEAD (3) TIGHTEN CONNECTOR.
Page 374 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 5 DIAGNOSIS AND TESTING (Continued) MULTI-FUNCTION SWITCH CONTINUITY TEST SWITCH POSITION MODE CONTINUITY BETWEEN TURN SIGNAL IN NEUTRAL NEUTRAL B-1 AND B-4 HAZARD WARNING SWITCH OFF B-1 AND B-5 TURN SIGNAL ON LEFT TURN A-2 AND B-2 HAZARD WARNING SWITCH OFF...
Page 375 8J - 6 TURN SIGNAL AND HAZARD WARNING SYSTEMS DIAGNOSIS AND TESTING (Continued) REMOVAL AND INSTALLATION COMBINATION FLASHER The flasher is mounted to the back side of the multi-function switch (Fig. 2). The flasher is serviced separately from the multi-function switch. REMOVAL (1) Open hood.
Page 376 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 7 REMOVAL AND INSTALLATION (Continued) INSTALLATION NOTE: • If replacing the multi-function switch, the com- bination flasher must be transferred to new switch. • If replacing the multi-function switch, the wind- shield wiper/washer switch must be transferred to the new switch.
Page 378 2001 PT CRUISER TURN SIGNAL and HAZARD WARNING SYSTEMS 8Ja - 1 TURN SIGNAL and HAZARD WARNING SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION REAR FOG LAMP SWITCH....1 REAR FOG LAMP SWITCH.
Page 379 2001 PT CRUISER 8Ja - 2 TURN SIGNAL and HAZARD WARNING SYSTEMS DIAGNOSIS AND TESTING (2) Remove the upper and lower steering column shrouds. Refer Instrument Panel Systems, Removal and Installation, Steering Column Shrouds. MULTI-FUNCTION with REAR FOG SWITCH (3) Disconnect the switch connector. Using an ohmmeter, test for continuity (no resis- FLASHER DIAGNOSIS tance) between the terminals of the switch as shown...
Page 380 2001 PT CRUISER TURN SIGNAL and HAZARD WARNING SYSTEMS 8Ja - 3 DIAGNOSIS AND TESTING (Continued) MULTI-FUNCTION SWITCH CONTINUITY TEST SWITCH POSITION MODE CONTINUITY BETWEEN TURN SIGNAL IN NEUTRAL NOTHING ON 1,4,5 AND 18,19 HAZARD WARNING SWITCH OFF TURN SIGNAL ON LEFT TURN 1,5 AND 2,4 AND 18,19 HAZARD WARNING SWITCH OFF...
Page 381 2001 PT CRUISER...
Page 382 WIPER AND WASHER SYSTEMS 8K - 1 WIPER AND WASHER SYSTEMS TABLE OF CONTENTS page page FRONT WINDSHIELD WIPER/WASHER REAR WINDSHIELD WIPER/WASHER SYSTEM ....... . 1 SYSTEM .
Page 383 8K - 2 WIPER AND WASHER SYSTEMS DESCRIPTION AND OPERATION (Continued) Fig. 1 Windshield Wiper/Washer Switch Location 1 – TURN SIGNAL CONTROL STALK 5 – CANCELLING CAM 2 – HAZARD WARNING SWITCH 6 – PANEL DIMMER/INTERIOR LIGHT SWITCH 3 – WINDSHIELD WIPER/WASHER CONTROL 7 –...
Page 384 WIPER AND WASHER SYSTEMS 8K - 3 DESCRIPTION AND OPERATION (Continued) lever (Fig. 1). The lever is located on the right side of OPERATION the steering column. Each nozzle emits two streams into the wiper pat- The electric pump assembly is mounted directly to tern (Fig.
Page 385 8K - 4 WIPER AND WASHER SYSTEMS DIAGNOSIS AND TESTING (Continued) tor. Connect the other jumper wire to the battery (a) If fuse does not blow, replace motor. negative terminal and terminal 1 (Fig. 5). Check (b) If fuse blows, disconnect wiper switch and motor high speed, connect the positive jumper wire to replace fuse.
Page 386 WIPER AND WASHER SYSTEMS 8K - 5 DIAGNOSIS AND TESTING (Continued) WIPERS DO NOT OPERATE WHEN WASHER FRONT WINDSHIELD WIPER MOTOR MOTOR IS ENGAGED (PULSE WIPE) OR WIPERS Whenever a wiper motor malfunction occurs, verify that the wire harness is properly connected, then DO OPERATE IN INTERMITTENT POSITION.
Page 387 8K - 6 WIPER AND WASHER SYSTEMS DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION WIPER MOTOR WILL NOT (1) BLOWN FUSE. (1) REPLACE FUSE, AND RUN SYSTEM. RUN. (2) NEW FUSE BLOWS. (2) CHECK FOR SHORT IN WIRING OR (3) NEW FUSE BLOWS.
Page 388 WIPER AND WASHER SYSTEMS 8K - 7 DIAGNOSIS AND TESTING (Continued) FRONT AND REAR WINDSHIELD WASHER SYSTEM TEST CONDITION POSSIBLE CAUSES CORRECTION PUMP RUNS NO FLUID 1. NO FLUID IN THE 1. FILL RESERVOIR. FLOWING. RESERVOIR. 2. THAW AND CHECK FLOW IF BLOCKED 2.
Page 389 8K - 8 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) INSTALLATION (2) Disconnect and isolate the battery negative cable (Fig. 12). (1) Install blade assembly on arm by pushing tab under the hook on the arm tip and slide blade into arm tip until it clicks (Fig.
Page 390 WIPER AND WASHER SYSTEMS 8K - 9 REMOVAL AND INSTALLATION (Continued) (9) Verify vehicle and system operation. FRONT WINDSHIELD WIPER MOTOR REMOVAL To service the front windshield wiper motor, the front windshield wiper module must first removed. (1) Open hood. (2) Disconnect and isolate the battery negative cable (Fig.
Page 391 8K - 10 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) (c) Install the rear engine compartment seal at the cowl. Before installation of the front windshield wiper arms, activate the wiper system to ensure the wiper module is in the PARK position. Position wiper arms so that the tip of the driver’s blade and the middle of the passenger’s blade is on the park line on the wind- shield.
Page 392 WIPER AND WASHER SYSTEMS 8K - 11 REMOVAL AND INSTALLATION (Continued) (4) Lower hood down. (5) Using a plastic body filler spreader or equiva- lent (credit card), gently place it underneath the front of the washer nozzle. Be careful not to damage the hood seal underneath the nozzle.
Page 393 8K - 12 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 18 Body Hose Routing Fig. 19 Hood Hose Routing - Typical (2) Insert pump into pump grommet and firmly (5) Install the three reservoir retaining screws. snap into reservoir. Torque screws to 8 N·m (70 in.
Page 394 WIPER AND WASHER SYSTEMS 8K - 13 REMOVAL AND INSTALLATION (Continued) WINDSHIELD WASHER RESERVOIR INSTALLATION (1) Insert pump into pump grommet and firmly REMOVAL snap into reservoir. (2) Place reservoir into cowl area and connect the (1) Open hood. washer hoses (Fig. 20). (2) Turn wipers ON, while the key is in the ACCESSORY position and when the blades are at NOTE: The hose with the white stripe goes on the...
Page 395 8K - 14 WIPER AND WASHER SYSTEMS ADJUSTMENTS (Continued) (4) Remove the arm from the pivot using a rocking motion while the arm is in an over/centered position (Fig. 9). (5) The wiper blade should be within the tolerance shown within the tick mark. The park line or tick mark, is on the windshield (Fig.
Page 396 WIPER AND WASHER SYSTEMS 8K - 15 REAR WINDSHIELD WIPER/WASHER SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION REAR WINDSHIELD WIPER SYSTEM ..15 REAR WINDSHIELD WIPER ARM ... . 17 REAR WINDSHIELD WASHER SYSTEM .
Page 397 8K - 16 WIPER AND WASHER SYSTEMS DESCRIPTION AND OPERATION (Continued) NOTE: The washers will stop spraying if the switch DIAGNOSIS AND TESTING is pressed longer than 30 seconds. REAR WINDSHIELD WIPER/WASHER DIAGNOSTICS REAR WINDSHIELD WASHER SYSTEM The rear window wiper system operates in several modes: DESCRIPTION •...
Page 398 WIPER AND WASHER SYSTEMS 8K - 17 DIAGNOSIS AND TESTING (Continued) (8) Reconnect the battery negative cable. Check for (2) With switch removed from vehicle, use a battery voltage at the fused B(+) circuit cavity of the jumper wire and connect a 12 volt supply to Pin 1 liftgate wire harness connector for the rear wiper and 2.
Page 399 8K - 18 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 6 Rear Windshield Wiper Arm/Blade Tick Mark Fig. 5 Rear Windshield Wiper Arm Remove/Install 1 – EBL GRID LINES INSTALLATION 2 – TICK MARK Before installation activate wiper system to ensure the wiper module is in the PARK position.
Page 400 WIPER AND WASHER SYSTEMS 8K - 19 REMOVAL AND INSTALLATION (Continued) INSTALLATION Before installation activate wiper system to ensure the wiper module is in the PARK position. Position wiper arm so that the tip of the blade is on the park line on the glass.
Page 402 2001 PT CRUISER WIPER AND WASHER SYSTEMS 8Ka - 1 WIPER AND WASHER SYSTEMS TABLE OF CONTENTS page FRONT WINDSHIELD WIPER/WASHER SYSTEM – RHD ......1 FRONT WINDSHIELD WIPER/WASHER SYSTEM –...
Page 403 2001 PT CRUISER 8Ka - 2 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) (8) Remove three front windshield wiper module (a) Place the left side cowl cover into position mounting bolts and remove module from vehicle (Fig. and install the two push retainers. (b) Place the right side cowl cover into position and install the two push retainers.
Page 404 2001 PT CRUISER WIPER AND WASHER SYSTEMS 8Ka - 3 REMOVAL AND INSTALLATION (Continued) (10) Close hood. (11) Verify vehicle and system operation. WINDSHIELD WASHER HOSE - RHD REMOVAL For damaged or plugged windshield washer hose, remove the affected piece of hose and replace with bulk hose.
Page 405 2001 PT CRUISER 8Ka - 4 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 4 Body Hose Routing Fig. 5 Hood Hose Routing (2) Insert pump into pump grommet and firmly (5) Install the three reservoir retaining screws. snap into reservoir. Torque screws to 8 N·m (70 in.
Page 406 2001 PT CRUISER WIPER AND WASHER SYSTEMS 8Ka - 5 REMOVAL AND INSTALLATION (Continued) module is in the PARK position. Position wiper arms so that the heel of the blade(s) is on the park line on the windshield. Refer to Adjustments in this section for Wiper Arm Adjustment.
Page 407 2001 PT CRUISER 8Ka - 6 WIPER AND WASHER SYSTEMS ADJUSTMENTS (Continued) (3) Remove wiper arm retaining nut. (4) Remove the arm from the pivot using a rocking motion while the arm is in an over/centered position. (5) The wiper blade heel should be parked within 5 mm of the park line.
Page 408 LAMPS 8L - 1 LAMPS TABLE OF CONTENTS page page LAMP DIAGNOSIS ......1 LAMP SERVICE......12 HEADLAMP ALIGNMENT .
Page 409 8L - 2 LAMPS DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps and WITH ENGINE IDLING OR posts. IGNITION TURNED OFF 2. Loose or worn generator drive belt. 2.
Page 410 LAMPS 8L - 3 DIAGNOSIS AND TESTING (Continued) FOG LAMP FOG LAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps WITH ENGINE IDLING OR and posts. IGNITION TURNED OFF.
Page 411 8L - 4 LAMPS HEADLAMP ALIGNMENT TABLE OF CONTENTS page page DESCRIPTION AND OPERATION ADJUSTMENTS HEADLAMP ALIGNMENT ....4 HEADLAMP ADJUSTMENT USING SERVICE PROCEDURES ALIGNMENT SCREEN .
Page 412 LAMPS 8L - 5 ADJUSTMENTS (Continued) Fig. 1 Headlamp Alignment Screen 1 – CENTER OF HEADLAMPS 3 – 7.62 METERS (25 FT.) 2 – FRONT OF HEADLAMP...
Page 413 8L - 6 LAMPS ADJUSTMENTS (Continued) FOG LAMP ALIGNMENT in.) below the fog lamp center line and straight ahead Prepare an alignment screen. Refer to Alignment To adjust fog lamp alignment, rotate the alignment Screen Preparation paragraph in this section. Turn screw located on the side of the fog lamp from the on the headlamp switch tot he parking lamps only cooling opening in the fascia, just inboard of the fog...
Page 414 LAMPS 8L - 7 LAMP BULB SERVICE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION BACK UP LAMP BULB ....9 BULB .
Page 415 8L - 8 LAMPS REMOVAL AND INSTALLATION (Continued) FOG LAMP BULB REMOVAL (1) Reach behind the lower splash shield to gain access to the rear of the fog lamp (Fig. 2). (2) Disconnect wire connector from fog lamp. (3) Remove bulb from lamp. Fig.
Page 416 LAMPS 8L - 9 REMOVAL AND INSTALLATION (Continued) (5) Insert the lower positioning tab into the slot and then rotate the lamp forward until the retaining clips snap into position. (6) Slide the lamp assembly upwards within the opening. (7) Install tail lamp attaching screw. BACK UP LAMP BULB REMOVAL (1) Remove screws attaching the back up lamp...
Page 417 8L - 10 LAMPS REMOVAL AND INSTALLATION (Continued) Fig. 6 Back Up Lamp 1 – REAR FASCIA 4 – BULB 2 – BACKUP LAMP ASSY. 5 – CONNECTOR 3 – LICENSE PLATE LAMP Fig. 8 Transmission Range Indicator 1 – TRANSMISSION RANGE INDICATOR 2 –...
Page 418 LAMPS 8L - 11 REMOVAL AND INSTALLATION (Continued) Fig. 9 Lower Center Console Fig. 10 Cargo Lamp 1 – CONSOLE FLOOD LAMP 1 – JACK STORAGE AREA 2 – INSERT SMALL FLAT TOOL 2 – WIRE CONNECTOR 3 – CARGO LAMP HOUSING 4 –...
Page 419 8L - 12 LAMPS LAMP SERVICE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION TAIL, STOP AND TURN SIGNAL LAMP ..15 LAMP ASSEMBLIES ..... 12 BACK UP LAMP .
Page 420 LAMPS 8L - 13 REMOVAL AND INSTALLATION (Continued) Fig. 4 Headlamp Removal Fig. 2 Loosening The Fascia 1 – FASCIA FASTENER 1 – HEADLAMP HOUSING 2 – FRONT FASCIA 2 – ATTACHING POINT 3 – HEADLAMP HOUSING 3 – FRONT FASCIA Fig.
Page 421 8L - 14 LAMPS REMOVAL AND INSTALLATION (Continued) FOG LAMP FRONT SIDE MARKER/PARK/TURN SIGNAL LAMP HOUSING REMOVAL Refer to Headlamp Module removal procedures. (1) Remove fasteners attaching lower splash shield to gain access to the rear of the fog lamp (Fig. 6). CENTER HIGH MOUNTED STOP LAMP (2) Disconnect wire connector from fog lamp.
Page 422 LAMPS 8L - 15 REMOVAL AND INSTALLATION (Continued) Fig. 8 CHMSL Lamp Fig. 9 Tail and Stop Lamp 1 – CHMSL LAMP 1 – TAIL LAMP HOUSING 2 – LIFTGATE 2 – WIRE CONNECTORS 3 – BOTTOM LOCATOR TAIL, STOP AND TURN SIGNAL LAMP BACK UP LAMP REMOVAL (1) Remove screw attaching tail lamp assembly to...
Page 423 8L - 16 LAMPS REMOVAL AND INSTALLATION (Continued) Fig. 10 Back Up Lamp 1 – REAR FASCIA 4 – BULB 2 – BACKUP LAMP ASSY. 5 – CONNECTOR 3 – LICENSE PLATE LAMP CONSOLE FLOOD LAMP BULB REMOVAL (1) Using a flat blade tool, remove console flood lamp from the lower center console (Fig.
Page 424 LAMPS 8L - 17 REMOVAL AND INSTALLATION (Continued) REAR CARGO LAMP (5) Install jack storage door to the right rear quar- ter trim panel. (6) Close liftgate. REMOVAL (1) Open liftgate. DOME LAMP (2) Remove jack storage door from right rear quar- ter trim panel.
Page 425 8L - 18 LAMPS LAMP SYSTEMS TABLE OF CONTENTS page DESCRIPTION AND OPERATION DAYTIME RUNNING LAMP MODULE ..18 DESCRIPTION AND OPERATION cluster, then back out to the front turn signal switch lamps.
Page 426 LAMPS 8L - 19 BULB APPLICATION TABLE OF CONTENTS page page SPECIFICATIONS INTERIOR LAMPS ......19 EXTERIOR LAMPS......19 SPECIFICATIONS LAMP BULB...
Page 428 2001 PT CRUISER LAMPS 8La - 1 LAMPS TABLE OF CONTENTS page page EXPORT LAMP DESCRIPTION ....1 LAMP BULB SERVICE ..... . 7 LAMP DIAGNOSIS .
Page 429 2001 PT CRUISER 8La - 2 LAMPS DESCRIPTION AND OPERATION (Continued) FRONT POSITION LAMPS SIDE TURN SIGNAL REPEATER LAMPS DESCRIPTION DESCRIPTION Fig. 1 Front Position Lamp Location Fig. 2 Side Repeater Lamp Location 1 – LOW BEAM HEADLAMP 1 – SIDE REPEATER LAMP 2 –...
Page 430 2001 PT CRUISER LAMPS 8La - 3 LAMP DIAGNOSIS TABLE OF CONTENTS page page DIAGNOSIS AND TESTING FRONT POSITION LAMP DIAGNOSIS ..4 HEADLAMP LEVELING SYSTEM DIAGNOSIS ..3 SIDE REPEATER LAMP DIAGNOSIS .
Page 431 2001 PT CRUISER 8La - 4 LAMPS DIAGNOSIS AND TESTING (Continued) FRONT POSITION LAMP DIAGNOSIS SIDE REPEATER LAMP DIAGNOSIS The following test is designed to diagnosis a faulty The following test is designed to diagnosis a faulty front position lamp. Refer to Wiring Diagrams for a side repeater lamp.
Page 432 2001 PT CRUISER LAMPS 8La - 5 HEADLAMP ALIGNMENT TABLE OF CONTENTS page page SERVICE PROCEDURES ADJUSTMENTS HEADLAMP ALIGNMENT PREPARATION..5 HEADLAMP ADJUSTMENT USING ALIGNMENT SCREEN - EUROPEAN ..5 SERVICE PROCEDURES (2) Place 75 kg in the driver’s seat to simulate the ride height of the vehicle when driven.
Page 433 2001 PT CRUISER 8La - 6 LAMPS ADJUSTMENTS (Continued) Fig. 1 Headlamp Alignment Screen 1 – CENTER OF HEADLAMPS 2 – FRONT OF HEADLAMP HEADLAMP ADJUSTMENT To adjust headlamp alignment, rotate the align- ment screws (horizontal and vertical) to achieve A properly aimed low beam headlamp will project a the specified low beam spot pattern.
Page 434 2001 PT CRUISER LAMPS 8La - 7 LAMP BULB SERVICE TABLE OF CONTENTS page page REMOVAL AND INSTALLATION SIDE REPEATER LAMP BULB ....7 FRONT POSITION LAMP BULB ....7 DOME LAMP BULB .
Page 435 2001 PT CRUISER 8La - 8 LAMPS REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Push and twist bulb into socket. (2) Verify lamp operation. (3) Push side repeater lamp socket into side repeater lamp. (4) Position side repeater lamp to hole in fender. (5) Push side repeater lamp to one side and seat retaining tab into fender.
Page 436 2001 PT CRUISER LAMPS 8La - 9 LAMP SERVICE TABLE OF CONTENTS page page REMOVAL AND INSTALLATION SIDE REPEATER LAMP ....10 HEADLAMP MODULE - BUX .
Page 437 2001 PT CRUISER 8La - 10 LAMPS REMOVAL AND INSTALLATION (Continued) (2) Push and rotate leveling motor one quarter turn clockwise to lock motor to module housing. (3) Connect headlamp leveling motor electrical connector. (4) Install headlamp module in the vehicle. Refer to the procedure in this section of the service manual.
Page 438 2001 PT CRUISER LAMPS 8La - 11 REMOVAL AND INSTALLATION (Continued) DOME LAMP - INTRUSION SENSOR REMOVAL (1) Disconnect and isolate the negative battery cable. Fig. 5 (3) Disconnect dome lamp / intrusion sensor elec- trical connector. (4) Remove the lamp / intrusion sensor from the vehicle.
Page 439 2001 PT CRUISER 8La - 12 LAMPS BULB APPLICATION TABLE OF CONTENTS page page CLEANING AND INSPECTION EXTERIOR LAMP BULBS....12 HEADLAMP CLEANING ....12 SPECIFICATIONS INTRODUCTION .
Page 440 RESTRAINT SYSTEMS 8M - 1 RESTRAINT SYSTEMS TABLE OF CONTENTS page page FRONT AIRBAG SYSTEM ....1 SEAT BELT TENSIONER ....21 SIDE AIRBAG SYSTEM .
Page 441 An airbag indicator lamp in the instrument cluster NENTS ONLY WITH PARTS SPECIFIED IN THE lights for about six to eight seconds as a bulb test CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE each time the ignition switch is turned to the ON PARTS MAY APPEAR INTERCHANGEABLE, BUT position.
Page 442 NENTS ONLY WITH PARTS SPECIFIED IN THE The ORC contains a microprocessor, the impact CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE sensor, and energy storage capacitors. The micropro- PARTS MAY APPEAR INTERCHANGEABLE, BUT cessor contains the airbag system logic. The airbag...
Page 443 NENTS ONLY WITH PARTS SPECIFIED IN THE ule cover and the backer plate which is heat staked CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE on to the driver airbag module cover. PARTS MAY APPEAR INTERCHANGEABLE, BUT...
Page 444 RESTRAINT SYSTEMS 8M - 5 DESCRIPTION AND OPERATION (Continued) PASSENGER AIRBAG MODULE WARNING: DO NOT PLACE A NON-DEPLOYED AIR- BAG FACE DOWN ON A HARD SURFACE, THE AIR- WILL PROPEL INTO ACCIDENTALLY DEPLOYED, AND COULD RESULT IN SERIOUS OR FATAL INJURY. DESCRIPTION Fig.
Page 445 8M - 6 RESTRAINT SYSTEMS DESCRIPTION AND OPERATION (Continued) OPERATION The hybrid-type inflator assembly includes a small canister of highly compressed argon gas. The inflator seals the hole in the airbag cushion so it can dis- charge the gas it produces directly into the cushion when supplied with the proper electrical signal.
Page 446 CABLE BEFORE BEGINNING AIRBAG SYSTEM NOTE: If the Driver/Passenger Airbag Module is COMPONENT REMOVAL OR INSTALLATION PRO- defective and not deployed, refer to Chrysler Corpo- CEDURES. ALLOW SYSTEM CAPACITOR TO DIS- ration current return list for proper handling proce- CHARGE FOR TWO MINUTES BEFORE REMOVING dures.
Page 447 8M - 8 RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) OCCUPANT RESTRAINT CONTROLLER (ORC) INSTALLATION (1) Connect ORC connector and ensure that the WARNING: THE ORC CONTAINS THE SENSING connector and all locking tabs are engaged. ELEMENT SAFING SENSOR WHICH CAUTION: USE SUPPLIED NUTS ONLY ENABLES THE SYSTEM TO DEPLOY THE FRONT AIRBAGS.
Page 448 RESTRAINT SYSTEMS 8M - 9 REMOVAL AND INSTALLATION (Continued) Instrument Panel Systems, Steering Column Shroud (2) Connect the clockspring to the instrument Removal and Installation. panel harness, ensure wiring is properly routed. (7) Remove multi-function switch. Refer to Turn Then check that the connectors, locking tabs are Signal and Hazard Warning Systems, Multi-Function properly engaged and the halo lamp wire is in posi- Switch Removal and Installation.
Page 449 8M - 10 RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) REMOVAL (5) Using a pair of 90° internal snap ring pliers or equivalent, pry open the retaining clip (Fig. 13) and at he same time gently pry the pin away from the WARNING: WHEN REMOVING A DEPLOYED MOD- ULE, RUBBER GLOVES, EYE PROTECTION AND retaining clip, using a pocket screwdriver or equiva-...
Page 450 RESTRAINT SYSTEMS 8M - 11 REMOVAL AND INSTALLATION (Continued) INSTALLATION (4) Remove instrument panel top cover. Refer to Instrument Panel Systems, Instrument Panel Top (1) Connect the squib wire to the module. Make Cover Removal and Installation. airbag connection by pressing straight in on the con- (5) Open glove box, push in on the box/bin sides nector.
Page 451 8M - 12 RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) WARNING: DO NOT CONNECT BATTERY NEGA- TIVE CABLE YET. REFER FIRST TO DIAGNOSIS AND TESTING, AIRBAG SYSTEM TEST. (3) Close hood. (4) Verify vehicle and system operation. DEPLOYED MODULE REMOVAL When removing a deployed module, rubber gloves, eye protection, and a long-sleeved shirt should be worn, as there may be deposits on the surface which could irritate the skin and eyes.
Page 452 RESTRAINT SYSTEMS 8M - 13 REMOVAL AND INSTALLATION (Continued) (4) Install four passenger airbag cover screws along the bottom end of the airbag cover. Torque trim screws to 2 N·m (20 in. lbs.). (5) Install the right instrument panel end cap. Refer to Instrument Panel Systems, Removal and Installation, Instrument Panel End Cap.
Page 453 8M - 14 RESTRAINT SYSTEMS (c) After correcting active malfunction erase CLEANING AND INSPECTION stored Diagnostic Trouble Codes (DTC’s). CLEAN UP PROCEDURE Roll or fold the driver airbag towards the steering ADJUSTMENTS wheel and tape the airbag module cover over deployed bag.
Page 454 • REPLACE SIDE IMPACT AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN OPERATION THE CHRYSLER MOPAR PARTS CATALOG. SUBSTI- The side impact airbag control module (SIACM) TUTE PARTS MAY APPEAR INTERCHANGEABLE, controls the seat back mounted airbags. If the...
Page 455 8M - 16 RESTRAINT SYSTEMS DESCRIPTION AND OPERATION (Continued) SIDE IMPACT AIRBAG MODULES WARNING: DO NOT PLACE A NON-DEPLOYED SIDE AIRBAG FACE DOWN ON A HARD SURFACE, THE AIRBAG WILL PROPEL INTO THE AIR IF ACCI- DENTALLY DEPLOYED, AND COULD RESULT IN SERIOUS OR FATAL INJURY.
Page 456 ITY. WARNING: • THIS SYSTEM CONTAINS SENSITIVE, COM- NOTE: If the Side Impact Airbag Module is defec- PLEX ELECTRO-MECHANICAL UNITS. DISCON- tive and non-deployed, refer to Chrysler Corpora- NECT AND ISOLATE THE BATTERY NEGATIVE tion current return list proper handling CABLE BEFORE BEGINNING SIDE IMPACT AIRBAG procedures.
Page 457 8M - 18 RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 3 Battery Negative Cable Remove/Install Fig. 5 Side Impact Airbag Module Electrical Connector 1 – AIRBAG MODULE NYLON SLEEVE 2 – AIRBAG MODULE 3 – AIRBAG MODULE ELECTRICAL CONNECTOR (10) Working between seat back trim cover/cushion and frame carefully unhook airbag module studs from nylon sleeve and slide module out of sleeve.
Page 458 RESTRAINT SYSTEMS 8M - 19 REMOVAL AND INSTALLATION (Continued) CAUTION: The side impact airbag module must be WARNING: DO NOT CONNECT BATTERY NEGA- inside the nylon sleeve before installing retaining TIVE CABLE YET. REFER FIRST TO DIAGNOSIS nuts. Failure to do so will adversely affect the func- AND TESTING, AIRBAG SYSTEM TEST.
Page 459 8M - 20 RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) WARNING: DO NOT REMOVE SIACM FROM THE MOUNTING BRACKET. THIS IS SERVICED WITH THE BRACKET AND A NEW ONE WILL COME WITH THE REPLACEMENT SIACM. (6) Remove the SIACM retaining nuts and ground eyelet (Fig.
Page 460 RESTRAINT SYSTEMS 8M - 21 SEAT BELT TENSIONER TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION SEAT BELT TENSIONER SYSTEM ... . 21 SEAT BELT RETRACTOR....21 DIAGNOSIS AND TESTING SEAT BELT TENSIONER .
Page 462 ELECTRICALLY HEATED SYSTEMS 8N - 1 ELECTRICALLY HEATED SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REAR WINDOW DEFOGGER SYSTEM ..3 REAR WINDOW DEFOGGER SYSTEM ..1 SERVICE PROCEDURES REAR WINDOW DEFOGGER SWITCH .
Page 463 8N - 2 ELECTRICALLY HEATED SYSTEMS DESCRIPTION AND OPERATION (Continued) dow defogger switch LED indicator cannot be IN-VEHICLE TESTING repaired and, if faulty or damaged, the entire switch (1) Remove the switch from the instrument panel assembly must be replaced. but leave the switch connected, refer to Instrument Panel Systems, Accessory Switch Bezel Removal and OPERATION...
Page 464 ELECTRICALLY HEATED SYSTEMS 8N - 3 DIAGNOSIS AND TESTING (Continued) BENCH TESTING (1) First remove switch. Refer to Instrument Panel Systems, Accessory Switch Bezel Removal and Instal- lation. (2) With switch removed from vehicle, use a jumper wire and connect a 12 volt supply to Pin 1 and 2.
Page 465 8N - 4 ELECTRICALLY HEATED SYSTEMS (2) Follow instructions in repair kit for preparing SERVICE PROCEDURES damaged area. (3) Remove package separator clamp and mix plas- GRID LINE AND TERMINAL REPAIR tic conductive epoxy thoroughly. Fold in half and cut center corner to dispense epoxy.
Page 466 POWER DISTRIBUTION SYSTEMS 8O - 1 POWER DISTRIBUTION SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION POWER DISTRIBUTION SYSTEM... . . 1 CIGAR LIGHTER/AUXILIARY POWER CIGAR LIGHTER/AUXILIARY POWER OUTLET .
Page 467 8O - 2 POWER DISTRIBUTION SYSTEMS DESCRIPTION AND OPERATION (Continued) the console just in front of the cup holders (Fig. 2). This outlet can be used as a cigar lighter or power outlet, but only has 12 volt battery voltage when the ignition is in the ON or ACC positions.
Page 468 POWER DISTRIBUTION SYSTEMS 8O - 3 DESCRIPTION AND OPERATION (Continued) the heating element is recessed and shielded around its circumference for safety. POWER OUTLET (REAR CARGO AREA MOUNTED) The power outlet base or receptacle shell is con- nected to ground, and an insulated contact in the bottom of the shell is connected to battery current.
Page 469 8O - 4 POWER DISTRIBUTION SYSTEMS DESCRIPTION AND OPERATION (Continued) plastic PDC housing is located in the left front corner of the engine compartment, just behind the air cleaner housing and the battery. The PDC housing has a molded plastic cover. The PDC cover is easily removed for service access and has a convenient fuse and relay layout label affixed to the inside surface of the cover to ensure proper component identification.
Page 470 POWER DISTRIBUTION SYSTEMS 8O - 5 REMOVAL AND INSTALLATION (Continued) (4) With the instrument panel on the bench, de-trim the instrument panel enough to gain access to all screws and connectors to remove instrument panel wire harness with fuse block. INSTALLATION (1) Install the new wire harness and fuse block.
Page 471 8O - 6 POWER DISTRIBUTION SYSTEMS REMOVAL AND INSTALLATION (Continued) (2) Align the PDC on its mounting bracket and Refer to Wiring Diagrams for more information on install. the ground eyelet locations. (3) Route the engine compartment wire harness (5) Reconnect each of the engine compartment from the PDC through the engine compartment, wire harness connectors.
Page 472 POWER LOCK SYSTEMS 8P - 1 POWER LOCK SYSTEMS TABLE OF CONTENTS page page POWER DOOR LOCKS ..... . 1 REMOTE KEYLESS ENTRY (RKE).
Page 473 8P - 2 POWER LOCK SYSTEMS DESCRIPTION AND OPERATION (Continued) will mechanically unlock the door whose key cylinder CHILD PROTECTION LOCKS is being turned. A second turn of the key cylinder to the UNLOCK position (within five seconds of the DESCRIPTION first turn) will cause all vehicle doors to unlock elec- To provide a safer environment for children riding...
Page 474 POWER LOCK SYSTEMS 8P - 3 DIAGNOSIS AND TESTING (Continued) (5) To lock the door, connect a 12 volt power source DOOR LOCK SWITCH to one pin of the lock motor and a ground wire to the (1) Remove the switch from its mounting location, other pin.
Page 475 8P - 4 POWER LOCK SYSTEMS LIFTGATE LOCK MOTOR REMOVAL AND INSTALLATION DOOR LOCK MOTOR/LATCH REMOVAL (1) Open hood. The power door lock motor is integral to the door (2) Disconnect and isolate the battery negative latch. It is serviced with the latch as an assembly. cable (Fig.
Page 476 POWER LOCK SYSTEMS 8P - 5 REMOTE KEYLESS ENTRY (RKE) TABLE OF CONTENTS page page DESCRIPTION AND OPERATION TRANSMITTER PROGRAMMING ....7 REMOTE KEYLESS ENTRY SYSTEM ..5 REMOVAL AND INSTALLATION REMOTE KEYLESS ENTRY TRANSMITTER .
Page 477 8P - 6 POWER LOCK SYSTEMS DESCRIPTION AND OPERATION (Continued) tions. This mode is intended to be used when the received and acted upon. Illuminated entry is can- vehicle is on the dealer lot to provide VTSS coverage celled and the interior lamps are faded to off. •...
Page 478 POWER LOCK SYSTEMS 8P - 7 SERVICE PROCEDURES (Continued) (1) With the ignition switch in RUN position, press REMOVAL AND INSTALLATION and hold the transmitter Unlock button (Fig. 2) for a minimum of 4 seconds to a maximum of 10 seconds. REMOTE KEYLESS ENTRY (RKE) MODULE (2) While holding the UNLOCK button for 4-10 seconds, press the LOCK button (Fig.
Page 479 8P - 8 POWER LOCK SYSTEMS REMOVAL AND INSTALLATION (Continued) (5) Slide locking tab of the wiring connector side- ways to unlock tab, and remove connector from RKE module. (6) Remove RKE module from vehicle. NOTE: When replacing a faulty RKE Module, the replacement module must be configured with the DRB lll scan tool for proper operation.
Page 480 2001 PT CRUISER POWER LOCK SYSTEMS 8Pa - 1 POWER LOCK SYSTEMS TABLE OF CONTENTS page REMOTE KEYLESS ENTRY ....1 REMOTE KEYLESS ENTRY TABLE OF CONTENTS page page...
Page 481 2001 PT CRUISER 8Pa - 2 POWER LOCK SYSTEMS DESCRIPTION AND OPERATION (Continued) The receiver may receive signals from up to four vehicle from the assembly plant. Refer to Vehicle transmitters. Each transmitter has its own code, and Theft/Security Systems, Switching Operating the code is programmed and stored into ARKE mod-...
Page 482 2001 PT CRUISER POWER LOCK SYSTEMS 8Pa - 3 DESCRIPTION AND OPERATION (Continued) OPERATION (2) Disconnect and isolate the battery negative cable. Due to the radio frequency congestion in some (3) Remove the instrument panel top cover. Refer markets a external antenna must be used to assist in to Instrument Panel Systems, Instrument Pane Top frequency reception.
Page 483 2001 PT CRUISER 8Pa - 4 POWER LOCK SYSTEMS REMOVAL AND INSTALLATION (Continued) TRANSMITTER BATTERY INSTALLATION (1) Replace the batteries. Avoid touching the new REMOVAL batteries with your fingers, Skin oils may cause bat- tery deterioration. If you touch a battery, clean it off (1) With the transmitter buttons facing down, use with rubbing alcohol.
Page 484 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 1 VEHICLE THEFT/SECURITY SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION SENTRY KEY IMMOBILIZER SYSTEM VEHICLE THEFT/SECURITY SYSTEM (VTSS) . . . 1 INITIALIZATION ......5 SENTRY KEY IMMOBILIZER SYSTEM (SKIS) .
Page 485 8Q - 2 VEHICLE THEFT/SECURITY SYSTEMS DESCRIPTION AND OPERATION (Continued) LED will continue to flash at a slower rate indicating III scan tool as described in the proper Powertrain the system is armed. Diagnostic Procedures manual. If the hood ajar switch is not sensed by the system, SENTRY KEY IMMOBILIZER MODULE (SKIM) the indicator LED will remain lit during the arming process, although the system will still arm.
Page 486 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 3 DESCRIPTION AND OPERATION (Continued) in memory. The SKIM also sends the “Secret Key” information on the “Customer Learn” programming code to each of the programmed Sentry Key tran- mode. sponders. The security code is used by the assembly For diagnosis or initialization of the SKIM and the plant to access the SKIS for initialization, or by the PCM, a DRB III...
Page 487 8Q - 4 VEHICLE THEFT/SECURITY SYSTEMS DESCRIPTION AND OPERATION (Continued) SENTRY KEY IMMOBILIZER TRANSPONDER the SKIM transceiver issues a Radio Frequency (RF) signal that excites the transponder chip. The tran- sponder chip responds by issuing an RF signal con- DESCRIPTION taining its transponder identification code and the “Secret Key”...
Page 488 SKIM from the vehicle SERVICE PROCEDURES owner, the vehicle’s invoice or from Chrysler’s Cus- tomer Center. REMOTE KEYLESS ENTRY (RKE)/VEHICLE (2) With the DRB III scan tool, select “Theft THEFT/SECURITY SYSTEM (VTSS) - Alarm,”...
Page 489 8Q - 6 VEHICLE THEFT/SECURITY SYSTEMS SERVICE PROCEDURES (Continued) (7) Program all customer keys into the SKIM’s (6) About ten seconds after the completion of Step memory. This required that the SKIM be in secured 5, a single audible chime tone will sound and the access mode The SKIM will immediately exit VTSS indicator LED will stop flashing and stay on secured access mode after each key is pro-...
Page 490 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 7 SERVICE PROCEDURES (Continued) lost or defective key, the “Erase All Keys” function (3) Turning the ignition to the ON position with an (requires entering secured access mode) has to be invalid key. performed. Then the customer’s seven keys plus the new key MUST be reprogrammed into the SKIM.
Page 491 8Q - 8 VEHICLE THEFT/SECURITY SYSTEMS REMOVAL AND INSTALLATION (Continued) (3) Install the front door trim panel. Refer to Body, (3) Remove the liftgate trim panel. Refer to Body, Front Door Trim Removal and Installation. Liftgate Trim Panel, Removal and Installation. (4) Connect the battery negative cable (Fig.
Page 492 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 9 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Install the RKE module on instrument panel. (2) Connect the wiring harness connector to the RKE module. Slide locking tab of the wiring connec- tor sideways to lock tab. (3) Install the two screws holding the RKE module to the instrument panel assembly (Fig.
Page 493 8Q - 10 VEHICLE THEFT/SECURITY SYSTEMS REMOVAL AND INSTALLATION (Continued) (1) Rotate the SKIM and its mounting bracket to the side towards the steering column to slide the SKIM antenna ring around the ignition switch lock cylinder housing and then downwards (Fig. 10). (2) Install the two screws securing the SKIM mod- ule to the top of the steering column (Fig.
Page 494 2001 PT CRUISER VEHICLE THEFT/SECURITY SYSTEM 8Qa - 1 VEHICLE THEFT/SECURITY SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION VTSS SIREN ......5 VEHICLE THEFT SECURITY SYSTEM.
Page 495 2001 PT CRUISER 8Qa - 2 VEHICLE THEFT/SECURITY SYSTEM DESCRIPTION AND OPERATION (Continued) • Rotating the drivers door key cylinder THREE NOTE: The dealer must remove the module from “Ship Mode” and place the ARKEM Module into times within FIVE seconds. This operation must be either the “Dealer Lot”...
Page 496 2001 PT CRUISER VEHICLE THEFT/SECURITY SYSTEM 8Qa - 3 DESCRIPTION AND OPERATION (Continued) SENTRY KEY IMMOBILIZER MODULE (SKIM) SKIM also stores in its memory the Vehicle Identifi- cation Number (VIN), which it learns through a PCI The Sentry Key Immobilizer Module (SKIM) (Fig. bus message from the PCM during initialization.
Page 497 2001 PT CRUISER 8Qa - 4 VEHICLE THEFT/SECURITY SYSTEM DESCRIPTION AND OPERATION (Continued) cannot be repaired, and if faulty or damaged, the the SKIM transceiver issues a Radio Frequency (RF) unit must be replaced. signal that excites the transponder chip. The tran- sponder chip responds by issuing an RF signal con- SENTRY KEY IMMOBILIZER SYSTEM taining its transponder identification code and the...
Page 498 2001 PT CRUISER VEHICLE THEFT/SECURITY SYSTEM 8Qa - 5 DESCRIPTION AND OPERATION (Continued) VTSS OPERATING FREQUENCIES The VTSS (RKE) system receives signals from the hand-held keyfob or transmitter. European market vehicles use 433 MHz. Japan market vehicles use 268 MHz. VTSS SIREN DESCRIPTION Fig.
Page 499 (1) Obtain vehicles unique number assigned to it’s original SKIM from the vehicle owner, the vehicle’s invoice or from Chrysler’s Cus- tomer Center. (2) With the DRB lll scan tool, select “Theft Alarm,” “SKIM,” Miscellaneous.” Select “SKIM Mod- ule Replaced” function and the DRB lll will prompt you through the following steps.
Page 500 2001 PT CRUISER VEHICLE THEFT/SECURITY SYSTEM 8Qa - 7 SERVICE PROCEDURES (Continued) NOTE: If a PCM is replaced, the unique “Secret diately return to normal system operation following Key” data must be transferred from the SKIM to the exit from the “Customer Learn” programming mode. PCM.
Page 501 2001 PT CRUISER 8Qa - 8 VEHICLE THEFT/SECURITY SYSTEM SERVICE PROCEDURES (Continued) • “Programming Key Failed” is displayed if fur- REMOVAL AND INSTALLATION ther diagnosis is required. • To learn additional keys, turn the ignition OFF, SIREN remove the learned key, and insert the next new blank key.
Page 502 2001 PT CRUISER VEHICLE THEFT/SECURITY SYSTEM 8Qa - 9 REMOVAL AND INSTALLATION (Continued) DOME LAMP - INTRUSION SENSOR REMOVAL (1) Disconnect and isolate the negative battery cable. Fig. 9 (3) Disconnect dome lamp / intrusion sensor elec- trical connector. (4) Remove the lamp / intrusion sensor from the vehicle.
Page 503 2001 PT CRUISER...
Page 504 POWER SEAT SYSTEMS 8R - 1 POWER SEAT SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION POWER SEAT SYSTEM ....1 FRONT SEAT ASSEMBLY .
Page 505 8R - 2 POWER SEAT SYSTEMS REMOVAL AND INSTALLATION (Continued) (4) Connect the battery negative cable (Fig. 1). (5) Close hood. (6) Verify vehicle and system operation. POWER FRONT SEAT SWITCH REMOVAL (1) Open hood. (2) Disconnect and isolate the battery negative cable (Fig.
Page 506 POWER WINDOW SYSTEMS 8S - 1 POWER WINDOW SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION WINDOW MOTOR......2 POWER WINDOW SYSTEM .
Page 507 8S - 2 POWER WINDOW SYSTEMS DESCRIPTION AND OPERATION (Continued) cal components, such as the regulator, lift plate, win- WINDOW MOTOR dow tracks, or glass, refer to Group Body. (1) Remove door trim panel. Refer to Group 23-Body, Front Door Trim Panel Removal and Instal- OPERATION lation.
Page 508 POWER WINDOW SYSTEMS 8S - 3 REMOVAL AND INSTALLATION (Continued) Fig. 4 Front Window Switch Remove Install Fig. 3 Battery Negative Cable Remove/Install INSTALLATION (1) With regulator on bench, install three screws retaining the motor to the regulator. (2) Install the window regulator. Refer to Body, Removal and Installation, Front Door Window Regu- lator/Rear Door Window Regulator.
Page 510 POWER MIRROR SYSTEMS 8T - 1 POWER MIRROR SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION POWER MIRROR SYSTEM....1 INSIDE REAR VIEW MIRROR ASSEMBLY .
Page 511 8T - 2 POWER MIRROR SYSTEMS DIAGNOSIS AND TESTING MIRROR SWITCH (1) Open hood. (2) disconnect and isolate the battery negative cable (Fig. 2). Fig. 3 Left Instrument Panel End Cover Remove/ Fig. 2 Battery Negative Cable Remove/Install Install (3) Remove the left lower instrument panel bezel. MIRROR SWITCH TEST TABLE Pull top rearward, lower to floor and with a quick pulling motion remove off instrument panel.
Page 512 POWER MIRROR SYSTEMS 8T - 3 DIAGNOSIS AND TESTING (Continued) REMOVAL AND INSTALLATION INSIDE REAR VIEW MIRROR ASSEMBLY REMOVAL (1) Open door. (2) Loosen mirror set screw. (3) Lift mirror from mounting button. INSTALLATION (1) Place mirror on mounting button. (2) Tighten mirror set screw.
Page 513 8T - 4 POWER MIRROR SYSTEMS REMOVAL AND INSTALLATION (Continued) INSTALLATION (6) Roll bezel upward and snap into place. (7) Connect the battery negative cable (Fig. 2). (1) Place the mirror switch in cover opening and (8) Close hood. firmly snap into place (Fig. 6). (9) Verify vehicle and system operation.
Page 514 2001 PT CRUISER POWER MIRRORS 8Ta - 1 POWER MIRRORS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION HEATED MIRROR TEST – POWER POWER FOLD-AWAY SIDE VIEW MIRRORS ..1 FOLD-AWAY – RHD ..... . 3 DIAGNOSIS AND TESTING REMOVAL AND INSTALLATION MIRROR SWITCH TEST - POWER...
Page 515 2001 PT CRUISER 8Ta - 2 POWER MIRRORS DIAGNOSIS AND TESTING (Continued) WOBBLE LEFT MIRROR RIGHT PLATE SELECTED MIRROR POSITION SELECTED CONTINUITY CONTINUITY BETWEEN BETWEEN PINS PINS ↓ 1, 3, 4, 9 3, 4, 6, 9 ↑ 1, 3, 4, 9 3, 4, 6, 9 →...
Page 516 2001 PT CRUISER POWER MIRRORS 8Ta - 3 DIAGNOSIS AND TESTING (Continued) (4) Disconnect mirror electrical connector and posi- tion as shown (Fig. 5). Fig. 4 Power Mirror Electrical Connector Fig. 5 Accessing Power Mirror Electrical Connector (5) Depress the mirror “retract”switch and using a 1 –...
Page 517 2001 PT CRUISER 8Ta - 4 POWER MIRRORS REMOVAL AND INSTALLATION (4) Disconnect power mirror switch electrical con- nector. (5) Remove the mirror switch retaining screws and POWER MIRROR SWITCH – RHD remove the switch from the end cover. REMOVAL INSTALLATION (1) Disconnect and isolate the negative battery (1) Connect mirror switch electrical and test func-...
Page 518 CHIME WARNING SYSTEMS 8U - 1 CHIME WARNING SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION CHIME WARNING SYSTEM ....1 CHIME.
Page 519 8U - 2 CHIME WARNING SYSTEMS (5) Check for NO voltage at Pin 14. Ignition volt- DIAGNOSIS AND TESTING age must not be present for the chime to work. (6) Check headlamp switch. FASTEN SEAT BELTS To test the fasten seat belts function, turn the igni- NO TONE WHEN KEY IS LEFT IN IGNITION AND tion switch to the ON position with the driver’s seat DRIVERS DOOR IS OPEN...
Page 520 OVERHEAD CONSOLE SYSTEMS 8V - 1 OVERHEAD CONSOLE SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION SERVICE PROCEDURES OVERHEAD CONSOLE SYSTEM ....1 COMPASS CALIBRATION ....3 AMBIENT TEMPERATURE SENSOR .
Page 521 8V - 2 OVERHEAD CONSOLE SYSTEMS DESCRIPTION AND OPERATION (Continued) OUTSIDE TEMPERATURE OPERATION Because engine temperature can increase the dis- The overhead console reading and courtesy lamps played temperature, causing the readings to be operate on battery current that is provided at all slowly updated.
Page 522 OVERHEAD CONSOLE SYSTEMS 8V - 3 2001 PT Service Manual DIAGNOSIS AND TESTING (Continued) Publication No. 81-370-1111 TSB 26-05-01 May, 2001 SENSOR TEST There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted sensor return circuit as (1) Turn the ignition switch to the OFF position.
Page 523 8V - 4 OVERHEAD CONSOLE SYSTEMS SERVICE PROCEDURES (Continued) important that you follow the instructions below exactly. (1) Be sure the ignition switch is in the OFF posi- tion before you begin the demagnetizing procedure. (2) Place an 8 1/2 in. X 11 in. piece of paper lengthwise on the roof of vehicle directly above com- pass.
Page 524 OVERHEAD CONSOLE SYSTEMS 8V - 5 REMOVAL AND INSTALLATION (Continued) (5) Align the front of the overhead console above (7) Close hood. the retaining slot and firmly snap into place connect (8) Calibrate compass. Refer to Service Procedures, the front retaining clip. Compass Calibration in this section.
Page 526 2001 PT CRUISER WIRING 8Wa - 1 WIRING TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION..8Wa-01-1 INTERIOR LIGHTING....8Wa-44-1 COMPONENT INDEX .
Page 527 2001 PT CRUISER...
Page 528 2001 PT CRUISER 8W-01 WIRING DIAGRAM INFORMATION 8Wa - 01 - 1 8W-01 WIRING DIAGRAM INFORMATION TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION CONNECTOR - MOLEX DESCRIPTION ......1 REMOVAL .
Page 529 2001 PT CRUISER 8Wa - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 1 WIRING DIAGRAM EXAMPLE 1...
Page 530 2001 PT CRUISER 8W-01 WIRING DIAGRAM INFORMATION 8Wa - 01 - 3 WIRING DIAGRAM INFORMATION (Continued) Fig. 2 WIRING DIAGRAM EXAMPLE 2...
Page 531 2001 PT CRUISER 8Wa - 01 - 4 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 3 WIRING DIAGRAM SYMBOLS...
Page 532 2001 PT CRUISER 8W-01 WIRING DIAGRAM INFORMATION 8Wa - 01 - 5 WIRING DIAGRAM INFORMATION (Continued) TERMINOLOGY TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA- LYTIC CONVERTER AND MUFFLER. This is a list of terms and definitions used in the wiring diagrams. WARNING: DO NOT ALLOW FLAME OR SPARKS LHD .
Page 533 2001 PT CRUISER 8Wa - 01 - 6 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) • Probing Tools - These tools are used for probing diagnosis. If the vehicle is equipped with these items, terminals in connectors (Fig. 4)Select the proper size disconnect them to verify these add-on items are not tool from Special Tool Package 6807, and insert it the cause of the problem.
Page 534 2001 PT CRUISER 8W-01 WIRING DIAGRAM INFORMATION 8Wa - 01 - 7 WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING FOR STANDARD PROCEDURE - TESTING FOR CONTINUITY SHORT TO GROUND ON FUSES POWERING (1) Remove the fuse for the circuit being checked SEVERAL LOADS or, disconnect the battery.
Page 535 2001 PT CRUISER 8Wa - 01 - 8 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) SPECIAL TOOLS CONNECTOR - AUGAT SPECIAL TOOLS - WIRING/TERMINAL REMOVAL (1) Disconnect battery. (2) Disconnect the connector from its mating half/ component. (3) Push down on the yellow connector locking tab to release the terminals (Fig.
Page 536 2001 PT CRUISER 8W-01 WIRING DIAGRAM INFORMATION 8Wa - 01 - 9 CONNECTOR - AUGAT (Continued) INSTALLATION (1) Reset the terminal locking tang. (2) Insert the removed wire in the same cavity on the repair connector. (3) Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities.
Page 537 2001 PT CRUISER 8Wa - 01 - 10 8W-01 WIRING DIAGRAM INFORMATION CONNECTOR - THOMAS AND BETTS (Continued) (4) Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). Fig. 14 SINGLE LOCK TAB 1 - SINGLE LOCK TAB Fig.
Page 538 2001 PT CRUISER 8W-01 WIRING DIAGRAM INFORMATION 8Wa - 01 - 11 TERMINAL REMOVAL (1) Disconnect battery. (2) Disconnect the connector being repaired from its mating half/component. (3) Remove connector locking wedge, required (Fig. 16). Fig. 18 TERMINAL REMOVAL USING SPECIAL TOOL 1 - FROM SPECIAL TOOL KIT 6680 2 - CONNECTOR (5) Cut the wire 6 inches from the back of the con-...
Page 539 2001 PT CRUISER 8Wa - 01 - 12 8W-01 WIRING DIAGRAM INFORMATION WIRE (5) Solder the connection together using rosin core type solder only (Fig. 21). STANDARD PROCEDURE - WIRE SPLICING CAUTION: DO NOT USE ACID CORE SOLDER. When splicing a wire, it is important that the cor- rect gage be used as shown in the wiring diagrams.
Page 540 2001 PT CRUISER 8W-02 COMPONENT INDEX 8Wa - 02 - 1 8W-02 COMPONENT INDEX Component Page Component Page A/C Compressor Clutch Relay ... 8Wa-42 Fuel Injectors ......8Wa-30 A/C Compressor Clutch .
Page 541 2001 PT CRUISER 8Wa - 02 - 2 8W-02 COMPONENT INDEX Component Page Component Page Passenger Heated Seat Cushion ..8Wa-63 Seat Belt Tensioners ....8Wa-43 Sentry Key Immobilizer Module .
Page 542 2001 PT CRUISER 8W-10 POWER DISTRIBUTION 8Wa - 10 - 1 8W-10 POWER DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8Wa-10-11 Fuse 17 (FB) ..... . . 8Wa-10-8 A/C Compressor Clutch Relay .
Page 543 2001 PT CRUISER...
Page 544 2001 PT CRUISER...
Page 545 2001 PT CRUISER...
Page 546 2001 PT CRUISER...
Page 547 2001 PT CRUISER...
Page 548 2001 PT CRUISER...
Page 549 2001 PT CRUISER...
Page 550 2001 PT CRUISER...
Page 551 2001 PT CRUISER...
Page 552 2001 PT CRUISER...
Page 553 2001 PT CRUISER...
Page 554 2001 PT CRUISER...
Page 555 2001 PT CRUISER...
Page 556 2001 PT CRUISER...
Page 557 2001 PT CRUISER...
Page 558 2001 PT CRUISER...
Page 559 2001 PT CRUISER...
Page 560 2001 PT CRUISER...
Page 561 2001 PT CRUISER...
Page 562 2001 PT CRUISER 8W-11 FUSE BLOCK 8Wa - 11 - 1 8W-11 FUSE BLOCK Component Page Component Page A/C Compressor Clutch Relay ..8Wa-11-13 High Speed Radiator Fan Relay ..8Wa-11-13 Back-Up Lamp Switch .
Page 563 2001 PT CRUISER...
Page 564 2001 PT CRUISER...
Page 565 2001 PT CRUISER...
Page 566 2001 PT CRUISER...
Page 567 2001 PT CRUISER...
Page 568 2001 PT CRUISER...
Page 569 2001 PT CRUISER...
Page 570 2001 PT CRUISER...
Page 571 2001 PT CRUISER...
Page 572 2001 PT CRUISER...
Page 573 2001 PT CRUISER...
Page 574 2001 PT CRUISER...
Page 575 2001 PT CRUISER...
Page 576 2001 PT CRUISER...
Page 577 2001 PT CRUISER...
Page 578 2001 PT CRUISER...
Page 579 2001 PT CRUISER...
Page 580 2001 PT CRUISER 8W-15 GROUND DISTRIBUTION 8Wa - 15 - 1 8W-15 GROUND DISTRIBUTION Component Page Component Page A/C Compressor Clutch ... . . 8Wa-15-4, 10 Left Turn Signal Indicator ..8Wa-15-16, 21 A/C Compressor Clutch Relay .
Page 581 2001 PT CRUISER...
Page 582 2001 PT CRUISER...
Page 583 2001 PT CRUISER...
Page 584 2001 PT CRUISER...
Page 585 2001 PT CRUISER...
Page 586 2001 PT CRUISER...
Page 587 2001 PT CRUISER...
Page 588 2001 PT CRUISER...
Page 589 2001 PT CRUISER...
Page 590 2001 PT CRUISER...
Page 591 2001 PT CRUISER...
Page 592 2001 PT CRUISER...
Page 593 2001 PT CRUISER...
Page 594 2001 PT CRUISER...
Page 595 2001 PT CRUISER...
Page 596 2001 PT CRUISER...
Page 597 2001 PT CRUISER...
Page 598 2001 PT CRUISER...
Page 599 2001 PT CRUISER...
Page 600 2001 PT CRUISER...
Page 601 2001 PT CRUISER...
Page 602 2001 PT CRUISER...
Page 603 2001 PT CRUISER...
Page 604 2001 PT CRUISER...
Page 605 2001 PT CRUISER...
Page 606 2001 PT CRUISER 8W-18 BUS COMMUNICATIONS 8Wa - 18 - 1 8W-18 BUS COMMUNICATIONS Component Page Component Page Controller Antilock Brake ... . . 8Wa-18-2 Power Distribution Center ... . 8Wa-18-2 Data Link Connector .
Page 607 2001 PT CRUISER...
Page 608 2001 PT CRUISER...
Page 609 2001 PT CRUISER...
Page 610 2001 PT CRUISER 8W-20 CHARGING SYSTEM 8Wa - 20 - 1 8W-20 CHARGING SYSTEM Component Page Component Page Automatic Shut Down Relay ... 8Wa-20-2 G100 ......8Wa-20-2 Battery .
Page 611 2001 PT CRUISER...
Page 612 2001 PT CRUISER 8W-21 STARTING SYSTEM 8Wa - 21 - 1 8W-21 STARTING SYSTEM Component Page Component Page Battery ......8Wa-21-2 Generator .
Page 613 2001 PT CRUISER...
Page 614 2001 PT CRUISER 8W-30 FUEL/IGNITION SYSTEM 8Wa - 30 - 1 8W-30 FUEL/IGNITION SYSTEM Component Page Component Page A/C Compressor Clutch Relay ..8Wa-30-8 G102 ..... . . 8Wa-30-2, 11, 12 A/C Pressure Transducer .
Page 615 2001 PT CRUISER...
Page 616 2001 PT CRUISER...
Page 617 2001 PT CRUISER...
Page 618 2001 PT CRUISER...
Page 619 2001 PT CRUISER...
Page 620 2001 PT CRUISER...
Page 621 2001 PT CRUISER...
Page 622 2001 PT CRUISER...
Page 623 2001 PT CRUISER...
Page 624 2001 PT CRUISER...
Page 625 2001 PT CRUISER...
Page 626 2001 PT CRUISER...
Page 627 2001 PT CRUISER...
Page 628 2001 PT CRUISER 8W-31 TRANSMISSION CONTROL SYSTEM 8Wa - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM Component Page Component Page Brake Lamp Switch ....8Wa-31-3 Left Back-Up Lamp .
Page 629 2001 PT CRUISER...
Page 630 2001 PT CRUISER...
Page 631 2001 PT CRUISER...
Page 632 2001 PT CRUISER...
Page 633 2001 PT CRUISER...
Page 634 2001 PT CRUISER...
Page 635 2001 PT CRUISER...
Page 636 2001 PT CRUISER 8W-33 VEHICLE SPEED CONTROL 8Wa - 33 - 1 8W-33 VEHICLE SPEED CONTROL Component Page Component Page Brake Lamp Switch ....8Wa-33-3 Instrument Cluster .
Page 637 2001 PT CRUISER...
Page 638 2001 PT CRUISER...
Page 639 2001 PT CRUISER...
Page 640 2001 PT CRUISER...
Page 641 2001 PT CRUISER...
Page 642 2001 PT CRUISER 8W-35 ANTILOCK BRAKES 8Wa - 35 - 1 8W-35 ANTILOCK BRAKES Component Page Component Page Brake Lamp Switch ....8Wa-35-2 G201 ......8Wa-35-3 Controller Antilock Brake .
Page 643 2001 PT CRUISER...
Page 644 2001 PT CRUISER...
Page 645 2001 PT CRUISER...
Page 646: Table Of Contents
2001 PT CRUISER 8W-39 VEHICLE THEFT SECURITY SYSTEM 8Wa - 39 - 1 8W-39 VEHICLE THEFT SECURITY SYSTEM Component Page Component Page Data Link Connector ....8Wa-39-3, 16 Left Lavalier Module .
Page 647 2001 PT CRUISER...
Page 648 2001 PT CRUISER...
Page 649 2001 PT CRUISER...
Page 650 2001 PT CRUISER...
Page 651 2001 PT CRUISER...
Page 652 2001 PT CRUISER...
Page 653 2001 PT CRUISER...
Page 654 2001 PT CRUISER...
Page 655 2001 PT CRUISER...
Page 656 2001 PT CRUISER...
Page 657 2001 PT CRUISER...
Page 658 2001 PT CRUISER...
Page 659 2001 PT CRUISER...
Page 660 2001 PT CRUISER...
Page 661 2001 PT CRUISER...
Page 662 2001 PT CRUISER...
Page 663 2001 PT CRUISER...
Page 664 2001 PT CRUISER 8W-40 INSTRUMENT CLUSTER 8Wa - 40 - 1 8W-40 INSTRUMENT CLUSTER Component Page Component Page A/C- Heater Control Switch ... 8Wa-40-14 Left Front Door Ajar Switch ....8Wa-40-7, 8, 9, 10, 11 Cargo Lamp .
Page 665 2001 PT CRUISER...
Page 666 2001 PT CRUISER...
Page 667 2001 PT CRUISER...
Page 668 2001 PT CRUISER...
Page 669 2001 PT CRUISER...
Page 670 2001 PT CRUISER...
Page 671 2001 PT CRUISER...
Page 672 2001 PT CRUISER...
Page 673 2001 PT CRUISER...
Page 674 2001 PT CRUISER...
Page 675 2001 PT CRUISER...
Page 676 2001 PT CRUISER...
Page 677 2001 PT CRUISER...
Page 678 2001 PT CRUISER...
Page 679 2001 PT CRUISER...
Page 680 2001 PT CRUISER...
Page 681 2001 PT CRUISER...
Page 682 2001 PT CRUISER...
Page 683 2001 PT CRUISER...
Page 684 2001 PT CRUISER 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8Wa - 41 - 1 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET Component Page Component Page Cigar Lighter ..... . 8Wa-41-3 Horn Relay .
Page 685 2001 PT CRUISER...
Page 686 2001 PT CRUISER...
Page 687 2001 PT CRUISER...
Page 688 2001 PT CRUISER 8W-42 AIR CONDITIONING-HEATER 8Wa - 42 - 1 8W-42 AIR CONDITIONING-HEATER Component Page Component Page A/C Compressor Clutch ....8Wa-42-2 Fuse 12 (FB) ..... 8Wa-42-2, 4 A/C Compressor Clutch Relay .
Page 689 2001 PT CRUISER...
Page 690 2001 PT CRUISER...
Page 691 2001 PT CRUISER...
Page 692 2001 PT CRUISER 8W-43 OCCUPANT RESTRAINT SYSTEM 8Wa - 43 - 1 8W-43 OCCUPANT RESTRAINT SYSTEM Component Page Component Page Clockspring ......8Wa-43-3 Left Seat Airbag .
Page 693 2001 PT CRUISER...
Page 694 2001 PT CRUISER...
Page 695 2001 PT CRUISER...
Page 696 2001 PT CRUISER 8W-44 INTERIOR LIGHTING 8Wa - 44 - 1 8W-44 INTERIOR LIGHTING Component Page Component Page A/C- Heater Control Switch ... 8Wa-44-5 Instrument Cluster ....8Wa-44-2, 4, 5 Cargo Lamp .
Page 697 2001 PT CRUISER...
Page 698 2001 PT CRUISER...
Page 699 2001 PT CRUISER...
Page 700 2001 PT CRUISER...
Page 701 2001 PT CRUISER...
Page 702 2001 PT CRUISER 8W-47 AUDIO SYSTEM 8Wa - 47 - 1 8W-47 AUDIO SYSTEM Component Page Component Page Data Link Connector ....8Wa-47-2 Left Front Door Speaker ... . 8Wa-47-4, 5 Fuse 2 (FB) .
Page 703 2001 PT CRUISER...
Page 704 2001 PT CRUISER...
Page 705 2001 PT CRUISER...
Page 706 2001 PT CRUISER...
Page 707 2001 PT CRUISER...
Page 708 2001 PT CRUISER 8W-48 REAR WINDOW DEFOGGER 8Wa - 48 - 1 8W-48 REAR WINDOW DEFOGGER Component Page Component Page A/C- Heater Control Switch ... 8Wa-48-2 G300 ......8Wa-48-2 Fuse 6 (FB) .
Page 709 2001 PT CRUISER...
Page 710 2001 PT CRUISER 8W-49 OVERHEAD CONSOLE 8Wa - 49 - 1 8W-49 OVERHEAD CONSOLE Component Page Component Page Ambient Temperature Sensor ..8Wa-49-2 G204 ......8Wa-49-3 Fuse 14 (FB) .
Page 711 2001 PT CRUISER...
Page 712 2001 PT CRUISER...
Page 713 2001 PT CRUISER...
Page 714 2001 PT CRUISER 8W-50 FRONT LIGHTING 8Wa - 50 - 1 8W-50 FRONT LIGHTING Component Page Component Page Circuit Breaker No. 1 (FB) ... . 8Wa-50-2 Headlamp Switch ... 8Wa-50-2, 5, 6, 7, 8 Fuse 1 (FB) .
Page 715 2001 PT CRUISER...
Page 716 2001 PT CRUISER...
Page 717 2001 PT CRUISER...
Page 718 2001 PT CRUISER...
Page 719 2001 PT CRUISER...
Page 720 2001 PT CRUISER...
Page 721 2001 PT CRUISER...
Page 722 2001 PT CRUISER 8W-51 REAR LIGHTING 8Wa - 51 - 1 8W-51 REAR LIGHTING Component Page Component Page Back-Up Lamp Switch ....8Wa-51-2 Instrument Cluster ....8Wa-51-2 Brake Lamp Switch .
Page 723 2001 PT CRUISER...
Page 724 2001 PT CRUISER...
Page 725 2001 PT CRUISER...
Page 726 2001 PT CRUISER...
Page 727 2001 PT CRUISER...
Page 728 2001 PT CRUISER...
Page 729 2001 PT CRUISER...
Page 730 2001 PT CRUISER...
Page 731 2001 PT CRUISER...
Page 732 2001 PT CRUISER 8W-52 TURN SIGNALS 8Wa - 52 - 1 8W-52 TURN SIGNALS Component Page Component Page Fuse 15 (FB) ..... . . 8Wa-52-4 Left Front Side Marker .
Page 733 2001 PT CRUISER...
Page 734 2001 PT CRUISER...
Page 735 2001 PT CRUISER...
Page 736 2001 PT CRUISER...
Page 737 2001 PT CRUISER...
Page 738 2001 PT CRUISER 8W-53 WIPERS 8Wa - 53 - 1 8W-53 WIPERS Component Page Component Page Front Washer Pump Motor ..8Wa-53-2, 3, 5 G104 ......8Wa-53-2, 4 Front Wiper Motor .
Page 739 2001 PT CRUISER...
Page 740 2001 PT CRUISER...
Page 741 2001 PT CRUISER...
Page 742 2001 PT CRUISER...
Page 743 2001 PT CRUISER...
Page 744 2001 PT CRUISER 8W-60 POWER WINDOWS 8Wa - 60 - 1 8W-60 POWER WINDOWS Component Page Component Page Circuit Breaker No. 2 (FB) ..8Wa-60-2, 3, 6 Left Rear Power Window Motor ..8Wa-60-4, 7 Front Power Window Left Rear Power Window Switch .
Page 745 2001 PT CRUISER...
Page 746 2001 PT CRUISER...
Page 747 2001 PT CRUISER...
Page 748 2001 PT CRUISER...
Page 749 2001 PT CRUISER...
Page 750 2001 PT CRUISER...
Page 751 2001 PT CRUISER...
Page 752 2001 PT CRUISER 8W-61 POWER DOOR LOCKS 8Wa - 61 - 1 8W-61 POWER DOOR LOCKS Component Page Component Page Data Link Connector ....8Wa-61-9 Headlamp Switch .
Page 753 2001 PT CRUISER...
Page 754 2001 PT CRUISER...
Page 755 2001 PT CRUISER...
Page 756 2001 PT CRUISER...
Page 757 2001 PT CRUISER...
Page 758 2001 PT CRUISER...
Page 759 2001 PT CRUISER...
Page 760 2001 PT CRUISER...
Page 761 2001 PT CRUISER...
Page 762 2001 PT CRUISER...
Page 763 2001 PT CRUISER...
Page 764 2001 PT CRUISER 8W-62 POWER MIRRORS 8Wa - 62 - 1 8W-62 POWER MIRRORS Component Page Component Page Fuse 2 (FB) ......8Wa-62-2 Headlamp Switch .
Page 765 2001 PT CRUISER...
Page 766 2001 PT CRUISER...
Page 767 2001 PT CRUISER...
Page 768 2001 PT CRUISER...
Page 769 2001 PT CRUISER...
Page 770 2001 PT CRUISER 8W-63 POWER SEAT 8Wa - 63 - 1 8W-63 POWER SEAT Component Page Component Page Driver Heated Seat Back ... . . 8Wa-63-5 G201 ..... 8Wa-63-2, 3, 4, 5, 6 Driver Heated Seat Cushion .
Page 771 2001 PT CRUISER...
Page 772 2001 PT CRUISER...
Page 773 2001 PT CRUISER...
Page 774 2001 PT CRUISER...
Page 775 2001 PT CRUISER...
Page 776 2001 PT CRUISER 8W-64 POWER SUNROOF 8Wa - 64 - 1 8W-64 POWER SUNROOF Component Page Component Page Fuse 14 (FB) ..... . . 8Wa-64-2 Power Sunroof Module .
Page 777 2001 PT CRUISER...
Page 778 2001 PT CRUISER 8W-70 SPLICE INFORMATION 8Wa - 70 - 1 8W-70 SPLICE INFORMATION Component Page Component Page S100 ......8Wa-10-13 S213 .
Page 779 2001 PT CRUISER...
Page 780 2001 PT CRUISER...
Page 781 2001 PT CRUISER...
Page 782 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 1 8W-80 CONNECTOR PINOUTS Component Page Component Page A/C Compressor Clutch ....8Wa-80-4 C211 ......8Wa-80-21 A/C-Heater Control Switch .
Page 783 2001 PT CRUISER 8Wa - 80 - 2 8W-80 CONNECTOR PINOUTS Component Page Component Page Front Power Window Switch Left Tail/Stop Lamp ....8Wa-80-42 (Early Build) ....8Wa-80-32 Left Turn Signal Indicator .
Page 784 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 3 Component Page Component Page Right Fog Lamp ....8Wa-80-56 Right Rear Wheel Speed Sensor ..8Wa-80-60 Right Front Door Ajar Switch (Base) Right Seat Airbag .
Page 785 2001 PT CRUISER 8Wa - 80 - 4 8W-80 CONNECTOR PINOUTS A/C COMPRESSOR CLUTCH - BLACK 2 WAY CIRCUIT FUNCTION C3 20DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT Z1 20BK GROUND A/C-HEATER CONTROL SWITCH - GRAY 7 WAY CIRCUIT FUNCTION Z8 14BK/VT GROUND C7 14BK/TN BLOWER MOTOR HIGH DRIVER...
Page 786 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 5 BACK-UP LAMP SWITCH - GRAY 2 WAY CIRCUIT FUNCTION L1 18VT/BK BACK-UP LAMP FEED F20 18WT FUSED IGNITION SWITCH OUTPUT (RUN) BLOWER MOTOR - BLACK 2 WAY CIRCUIT FUNCTION C1 14DG FUSED IGNITION SWITCH OUTPUT (RUN) C7 14BK/TN...
Page 787 2001 PT CRUISER 8Wa - 80 - 6 8W-80 CONNECTOR PINOUTS BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID - WHITE 2 WAY CIRCUIT FUNCTION K29 20WT/PK BRAKE LAMP SWITCH SENSE F18 20LG/BK FUSED IGNITION SWITCH OUTPUT (RUN-START) BRAKE WARNING INDICATOR SWITCH - BLACK 2 WAY CIRCUIT FUNCTION G9 20GY/BK...
Page 788 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 7 C101 - BLACK (ENGINE SIDE) CIRCUIT K60 18YL/BK (NORMAL BUILD) K21 20BK/RD (EARLY BUILD) K21 18BK/RD (NORMAL BUILD) K6 20VT/WT K4 20BK/LB G7 20WT/OR (M/T) K141 20TN/WT K119 20LG/BK (M/T) T19 18WT (A/T) C102 - LT.
Page 789 2001 PT CRUISER 8Wa - 80 - 8 8W-80 CONNECTOR PINOUTS C103 - (INJECTOR HARNESS SIDE) CIRCUIT K4 20BK/LB K2 20TN/BK K11 18WT/DB K12 18TN K13 18YL/WT K14 18LB/BR A142 18DG/OR C103 - (ENGINE SIDE) CIRCUIT K4 20BK/LB K2 20TN/BK K11 18WT/DB K12 18TN K13 18YL/WT...
Page 790 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 9 C104 (A/T) - DK. GRAY (ENGINE SIDE) CIRCUIT T13 20DB/BK T52 20RD/BK T47 18YL/BK T1 20LG/BK T3 20VT T42 20VT/WT T50 18DG T54 18VT/PK T14 20LG/WT T9 18OR/BK T16 16RD T59 18PK T60 18BR T20 18LB...
Page 791 2001 PT CRUISER 8Wa - 80 - 10 8W-80 CONNECTOR PINOUTS C105 - (INSTRUMENT PANEL SIDE) CIRCUIT B27 18RD/YL (TRACTION CONTROL) L1 18VT/BK A1 14RD C7 14BK/TN M1 20PK A15 18PK/DG (EARLY BUILD) A15 18PK/DG (LHD NORMAL BUILD) A15 18PK/DB (RHD NORMAL BUILD) X5 20LB/RD (SIREN) L44 16VT/RD K29 20WT/PK...
Page 792 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 11 C106 - (HEADLAMP AND DASH SIDE) CIRCUIT A35 12DB (POWER MIRRORS NORMAL BUILD) L50 18WT/TN D25 20VT/YL V37 20RD/LG L13 20BR/YL (LAVALIER MODULE) F20 18WT A4 12BK/PK A2 12PK/BK F12 20DB/WT C5 18LG F39 18PK/LG (FOG LAMPS)
Page 793 2001 PT CRUISER 8Wa - 80 - 12 8W-80 CONNECTOR PINOUTS C109 - BLACK (UNDERBODY SIDE) CIRCUIT B1 20YL/DB B2 20YL B3 20LG/DB B4 20LG C109 - BLACK (HEADLAMP AND DASH SIDE) CIRCUIT B1 18YL/DB B2 18YL B3 18LG/DB B4 18LG C110 - BLACK (UNDERBODY SIDE) CIRCUIT G4 20DB...
Page 794 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 13 C200 - BLACK (INSTRUMENT PANEL SIDE) CIRCUIT E2 20PK (PREMIUM) F10 18YL/RD (PREMIUM) G31 20VT/LG (PREMIUM) G32 20BK/LB (PREMIUM EARLY BUILD) G32 20BK/LG (PREMIUM NORMAL BUILD) X53 18DG (EARLY BUILD) X53 18DG/VT (NORMAL BUILD) X55 18RD/BR (EARLY BUILD) X55 18BR/DB (NORMAL BUILD)
Page 795 2001 PT CRUISER 8Wa - 80 - 14 8W-80 CONNECTOR PINOUTS C202 - (INSTRUMENT PANEL SIDE) CIRCUIT G10 20LG/RD (NORMAL BUILD) G10 20LG/RD (RHD EARLY BUILD) G10 20LG/RD (EARLY BUILD) M9 20DB/OR C15 12BK/WT L50 18WT/TN X51 18BR/YL X57 18BR/LB P35 18OR/VT (RHD POWER LOCKS) P35 18OR/BK (LHD POWER LOCKS) P36 18PK/BK (LHD POWER LOCKS)
Page 796 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 15 C202 - (LEFT BODY SIDE) CIRCUIT Q23 14RD/DG (NORMAL BUILD) Q13 14DB/WT (EARLY BUILD) Q13 14DB/GY (NORMAL BUILD) L63 18DG/RD V13 18BR/LG P96 20WT/LG (POWER LOCKS) L1 18VT/BK G78 20TN/BK G75 20TN (EARLY BUILD) F13 18DB (EARLY BUILD) V23 18BR/BK (NORMAL BUILD)
Page 797 2001 PT CRUISER 8Wa - 80 - 16 8W-80 CONNECTOR PINOUTS C203 - GREEN (RIGHT BODY SIDE) CIRCUIT G74 20TN/RD G76 20TN/YL (EARLY BUILD) G76 20DB/OR (NORMAL BUILD) L50 18WT/TN X52 18DB/WT X58 18DB/BK P35 18OR/VT (POWER LOCKS) P36 18PK/VT (POWER LOCKS) Q14 14GY Q24 14DG L7 18BK/YL...
Page 798 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 17 C204 - NATURAL (INSTRUMENT PANEL SIDE) CIRCUIT C16 20LB/YL (POWER MIRRORS) Q11 14LB G75 20TN (LHD NORMAL BUILD) M9 20DB/OR (RHD NORMAL BUILD) P75 20DB/WT (POWER MIRRORS) L7 18BK/YL (POWER LOCKS) P159 20DG/WT (POWER FOLDING MIRROR) X53 18DG (EARLY BUILD) X53 18DG (EARLY BUILD)
Page 799 2001 PT CRUISER 8Wa - 80 - 18 8W-80 CONNECTOR PINOUTS C205 - NATURAL (INSTRUMENT PANEL SIDE) CIRCUIT C16 20LB/YL (POWER MIRRORS) Q12 12 BR/LB M9 20DB/OR (LHD NORMAL BUILD) G74 20TN/RD (RHD NORMAL BUILD) P74 20DB/WT (POWER MIRRORS) L7 18BK/YL (POWER LOCKS) P159 20DG/WT (POWER FOLDING MIRROR) X54 18VT/DG (EARLY BUILD)
Page 800 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 19 C206 (EARLY BUILD) - BLACK (INSTRUMENT PANEL SIDE) CIRCUIT A120 16RD/LG Z1 16BK C206 (EARLY BUILD) - BLACK (POWER HEIGHT ADJUSTER SIDE) CIRCUIT A120 16RD/LG Z1 16BK C207 - (DOME LAMP SIDE) CIRCUIT M1 20PK M2 20YL...
Page 801 2001 PT CRUISER 8Wa - 80 - 20 8W-80 CONNECTOR PINOUTS C208 - (LT/RT HEADLINER JUMPER SIDE) CIRCUIT E2 20PK F10 18YL G31 18BK G32 20BK/LG C209 - BLACK (INSTRUMENT PANEL SIDE) CIRCUIT C1 14DG C7 14BK/TN C209 - BLACK (LHD HEATER JUMPER SIDE) CIRCUIT C1 14DG C7 14BK/TN...
Page 802 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 21 C211 - (DOME LAMP SIDE) CIRCUIT Q43 20VT Q44 20BR Q42 20LB Q41 20WT Z1 18BK F10 18YL/RD C211 - (POWER SUNROOF SIDE) CIRCUIT L1 20VT L2 20BR L3 20LB L4 20WT Z1 14BK/VT L5 14YL/RD...
Page 803 2001 PT CRUISER 8Wa - 80 - 22 8W-80 CONNECTOR PINOUTS C301 - BLACK (REAR DOOR SIDE) CIRCUIT P35 18OR/VT (POWER LOCKS) P36 18PK/VT (POWER LOCKS) Q14 14DB/GY Q24 14RD/WT (EARLY BUILD) Q24 14RD/DG (NORMAL BUILD) C302 - (LIFTGATE SIDE) CIRCUIT P35 18OR/VT (POWER LOCKS) P36 18PK/VT (POWER LOCKS)
Page 804 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 23 C303 - (LEFT BODY SIDE) CIRCUIT L1 18VT/BK L38 18BR/WT (REAR FOG LAMPS) L7 18BK/YL Z1 18BK C303 - (REAR FASCIA SIDE) CIRCUIT L1 18VT/BK L38 18BR/WT (REAR FOG LAMPS) L7 18BK/YL Z1 18BK C304 - BLACK (FUEL TANK SIDE)
Page 805 2001 PT CRUISER 8Wa - 80 - 24 8W-80 CONNECTOR PINOUTS C305 (EARLY BUILD) - YELLOW (LEFT BODY SIDE) CIRCUIT R31 20LG/OR R33 20LG/WT C305 (EARLY BUILD) - YELLOW (SIDE AIR BAG SIDE) CIRCUIT R31 18OR R33 18WT C305 (NORMAL BUILD) - YELLOW (LEFT BODY SIDE) CIRCUIT R31 20LG/OR...
Page 806 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 25 C306 (EARLY BUILD) - YELLOW (SIDE AIR BAG SIDE) CIRCUIT R32 18OR R34 18WT C306 (NORMAL BUILD) - YELLOW (RIGHT BODY SIDE) CIRCUIT R32 20LB/OR R34 20LB/WT C306 (NORMAL BUILD) - YELLOW (SIDE AIR BAG SIDE) CIRCUIT R32 18OR...
Page 807 2001 PT CRUISER 8Wa - 80 - 26 8W-80 CONNECTOR PINOUTS CENTER HIGH MOUNTED STOP LAMP - BLACK 2 WAY CIRCUIT FUNCTION L50 18WT/TN BRAKE LAMP SWITCH OUTPUT Z1 18BK GROUND CENTER STACK LAMP - 2 WAY CIRCUIT FUNCTION E2 20OR PANEL LAMPS DRIVER Z1 20BK GROUND...
Page 808 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 27 CONTROLLER ANTILOCK BRAKE - 25 WAY CIRCUIT FUNCTION B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR SIGNAL B9 18RD LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUP- F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) B3 18LG/DB LEFT REAR WHEEL SPEED SENSOR SIGNAL B4 18LG...
Page 809 2001 PT CRUISER 8Wa - 80 - 28 8W-80 CONNECTOR PINOUTS DATA LINK CONNECTOR - BLACK 16 WAY CIRCUIT FUNCTION D25 20VT/YL PCI BUS Z12 20BK/TN GROUND Z11 20BK/WT GROUND D20 20LG SCI RECEIVE D21 20PK SCI TRANSMIT D6 20PK/LB (A/T) SCI RECEIVE (A/T) A14 18RD/WT FUSED B(+)
Page 810 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 29 DRIVER AIRBAG MODULE - YELLOW 2 WAY CIRCUIT FUNCTION R143 18BK/LB (NORMAL BUILD) DRIVER SQUIB NO. 1 LINE 1 R143 22BK/LB (EARLY BUILD) DRIVER SQUIB NO. 1 LINE 2 R145 18DG/LB (NORMAL BUILD) DRIVER SQUIB NO.
Page 811 2001 PT CRUISER 8Wa - 80 - 30 8W-80 CONNECTOR PINOUTS DRIVER DOOR POWER LOCK MOTOR/AJAR SWITCH (NORMAL BUILD) - BLACK 4 WAY CIRCUIT FUNCTION G74 18TN/DB (RHD) RIGHT FRONT DOOR AJAR SWITCH SENSE G75 18TN/DB (LHD) LEFT FRONT DOOR AJAR SWITCH SENSE Z1 18BK GROUND P34 18PK/BK...
Page 812 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 31 DRIVER SEAT BELT SWITCH - BLACK 2 WAY CIRCUIT FUNCTION G10 20LG/RD SEAT BELT SWITCH SENSE Z1 20BK GROUND EGR SOLENOID - BLACK 2 WAY CIRCUIT FUNCTION A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT K35 20GY/YL EGR SOLENOID CONTROL...
Page 813 2001 PT CRUISER 8Wa - 80 - 32 8W-80 CONNECTOR PINOUTS FRONT POWER WINDOW SWITCH (EARLY BUILD) - BLACK 8 WAY CIRCUIT FUNCTION Q12 14BR/LB RIGHT FRONT WINDOW DRIVER (UP) Q22 14VT/WT RIGHT FRONT WINDOW DRIVER (DOWN) F21 14TN FUSED IGNITION SWITCH OUTPUT (RUN) E2 20OR PANEL LAMPS DRIVER Q1 14YL...
Page 814 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 33 FRONT WIPER MOTOR - 5 WAY CIRCUIT FUNCTION Z1 18BK (RHD EARLY BUILD) GROUND Z1 16BK (LHD EARLY BUILD) GROUND Z1 16BK (NORMAL BUILD) GROUND V5 18DG WIPER SWITCH MODE SENSE F13 16DB (EARLY BUILD) FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F88 16RD/WT (NORMAL BUILD)
Page 815 2001 PT CRUISER 8Wa - 80 - 34 8W-80 CONNECTOR PINOUTS FUEL INJECTOR NO. 3 - BLACK 2 WAY CIRCUIT FUNCTION K13 18YL/WT FUEL INJECTOR NO. 3 DRIVER A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO. 4 - BLACK 2 WAY CIRCUIT FUNCTION K14 18LB/BR...
Page 816 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 35 HIGH NOTE HORN - BLACK 2 WAY CIRCUIT FUNCTION X2 20DG/RD HORN RELAY OUTPUT Z1 20BK GROUND HOOD AJAR SWITCH - BLACK 2 WAY CIRCUIT FUNCTION G70 20BR/TN HOOD AJAR SWITCH SENSE Z1 18BK (RHD) GROUND Z1 20BK (LHD)
Page 817 2001 PT CRUISER 8Wa - 80 - 36 8W-80 CONNECTOR PINOUTS INLET AIR TEMPERATURE SENSOR - BLACK 2 WAY CIRCUIT FUNCTION K21 20BK/RD (EARLY BUILD) INLET AIR TEMPERATURE SENSOR SIGNAL K21 18BK/RD (NORMAL BUILD) INLET AIR TEMPERATURE SENSOR SIGNAL K4 20BK/LB (EARLY BUILD) SENSOR GROUND K4 18BK/LB (NORMAL BUILD) SENSOR GROUND...
Page 818 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 37 INSTRUMENT CLUSTER C2 - BLACK 10 WAY CIRCUIT FUNCTION L39 18LB (FOG LAMPS) FOG LAMP SWITCH OUTPUT G69 20BK/OR (POWER MIRRORS) VTSS INDICATOR DRIVER L38 18BR/WT (BUILT-UP-EXPORT) REAR FOG LAMP SWITCH OUTPUT E19 20RD PANEL LAMPS DIMMER SIGNAL G4 20DB...
Page 819 2001 PT CRUISER 8Wa - 80 - 38 8W-80 CONNECTOR PINOUTS LEFT FRONT DOOR AJAR SWITCH (BASE) (NORMAL BUILD) - BLACK 2 WAY CIRCUIT FUNCTION G75 18TN/DB LEFT DOOR AJAR SWITCH SENSE Z1 18BK GROUND LEFT FRONT DOOR SPEAKER - BLACK 2 WAY CIRCUIT FUNCTION X53 18DG (EARLY BUILD)
Page 820 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 39 LEFT FRONT WHEEL SPEED SENSOR - BLACK 2 WAY CIRCUIT FUNCTION B9 18RD LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUP- B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR SIGNAL LEFT HIGH BEAM HEADLAMP - BLACK 2 WAY CIRCUIT FUNCTION...
Page 821 2001 PT CRUISER 8Wa - 80 - 40 8W-80 CONNECTOR PINOUTS LEFT LOW BEAM HEADLAMP - GRAY 2 WAY CIRCUIT FUNCTION L43 18VT (LHD) FUSED LEFT LOW BEAM OUTPUT L43 14VT (RHD) FUSED LEFT LOW BEAM OUTPUT Z1 12BK (LHD) GROUND Z1 14BK (RHD) GROUND...
Page 822 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 41 LEFT REAR POWER WINDOW MOTOR - BLACK 2 WAY CIRCUIT FUNCTION Q23 14RD/DG (NORMAL BUILD) LEFT REAR WINDOW DRIVER (DOWN) Q23 14RD/WT (EARLY BUILD) LEFT REAR WINDOW DRIVER (DOWN) Q13 14DB/GY LEFT REAR WINDOW DRIVER (UP) LEFT REAR POWER WINDOW SWITCH (NORMAL BUILD) - LT.
Page 823 2001 PT CRUISER 8Wa - 80 - 42 8W-80 CONNECTOR PINOUTS LEFT SEAT AIRBAG - 2 WAY CIRCUIT FUNCTION R31 18OR LEFT SEAT SQUIB LINE 2 R33 18WT LEFT SEAT SQUIB LINE 1 LEFT SEAT BELT TENSIONER - YELLOW 2 WAY CIRCUIT FUNCTION R53 18LG/YL...
Page 824 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 43 LEFT VISOR/VANITY LAMP - BLACK 2 WAY CIRCUIT FUNCTION M1 20PK FUSED B(+) Z1 20BK GROUND LICENSE LAMP (EXCEPT BUILT-UP-EXPORT) - NATURAL 2 WAY CIRCUIT FUNCTION L7 18BK/YL HEADLAMP SWITCH OUTPUT Z1 18BK GROUND LIFTGATE AJAR SWITCH - BLACK 2 WAY...
Page 825 2001 PT CRUISER 8Wa - 80 - 44 8W-80 CONNECTOR PINOUTS LOW NOTE HORN - BLACK 2 WAY CIRCUIT FUNCTION X2 20DG/RD HORN RELAY OUTPUT Z1 20BK GROUND MANIFOLD ABSOLUTE PRESSURE SENSOR - BLACK 3 WAY CIRCUIT FUNCTION K1 18DG/RD (NORMAL BUILD) MAP SENSOR SIGNAL K1 20DG/RD (EARLY BUILD) MAP SENSOR SIGNAL...
Page 826 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 45 MULTI-FUNCTION SWITCH - GRAY 20 WAY CIRCUIT FUNCTION A15 18PK/DG (LHD NORMAL BUILD) FUSED B(+) A15 18PK/DB (RHD NORMAL BUILD) FUSED B(+) L38 18BR/WT (BUILT-UP-EXPORT) HEADLAMP SWITCH OUTPUT L38 18BR/WT (BUILT-UP-EXPORT) HEADLAMP SWITCH OUTPUT F39 18PK/LG (EXCEPT BUILT-UP-EX- FUSED HEADLAMP RELAY OUTPUT...
Page 827 2001 PT CRUISER 8Wa - 80 - 46 8W-80 CONNECTOR PINOUTS OUTPUT SPEED SENSOR - GRAY 2 WAY CIRCUIT FUNCTION T13 20DB/BK SPEED SENSOR GROUND T14 20LG/WT OUTPUT SPEED SENSOR SIGNAL OVERHEAD CONSOLE MODULE - BLACK 12 WAY CIRCUIT FUNCTION Q41 20WT (POWER SUNROOF) SUNROOF OPEN Q44 20BR (POWER SUNROOF)
Page 828 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 47 PASSENGER AIRBAG - YELLOW 4 WAY CIRCUIT FUNCTION R44 18DG/YL PASSENGER SQUIB NO. 1 LINE 2 R42 18BK/YL PASSENGER SQUIB NO. 1 LINE 1 PASSENGER CYLINDER LOCK SWITCH - 2 WAY CIRCUIT FUNCTION P96 18LG...
Page 829 2001 PT CRUISER 8Wa - 80 - 48 8W-80 CONNECTOR PINOUTS PASSENGER HEATED SEAT CUSHION (NORMAL BUILD) - 4 WAY CIRCUIT FUNCTION Z122 18BK GROUND P130 18RD/TN PASSENGER SEAT HEATER B(+) DRIVER P142 20TN/DB PASSENGER SEAT TEMPERATURE SENSOR INPUT P144 20BK/LG PASSENGER SEAT TEMPERATURE 5V SUPPLY PASSENGER HEATED SEAT MODULE (NORMAL BUILD) - GREEN 14 WAY CIRCUIT...
Page 830 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 49 POWER MIRROR SWITCH (LHD) - BLACK 10 WAY CIRCUIT FUNCTION P73 20YL/PK LEFT MIRROR RIGHT/DOWN MOVEMENT P74 20DB/WT RIGHT MIRROR LEFT MOVEMENT Z1 20BK GROUND P71 20YL/BK LEFT MIRROR UP MOVEMENT L7 20BK/YL HEADLAMP SWITCH OUTPUT M1 20PK...
Page 831 2001 PT CRUISER 8Wa - 80 - 50 8W-80 CONNECTOR PINOUTS POWER SEAT MOTOR - 2 WAY CIRCUIT FUNCTION P120 16LG/YL (RHD) SEAT UP DRIVER P121 16LG/OR (LHD EXCEPT HEATED SEAT DOWN DRIVER SEATS) P121 16RD/LG (LHD HEATED SEATS) SEAT DOWN DRIVER P121 16LG/OR (RHD EXCEPT HEATED SEAT DOWN DRIVER SEATS)
Page 832 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 51 POWER SUNROOF MODULE C2 - 4 WAY CIRCUIT FUNCTION L5 14YL/RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC) L7 14DB MOTOR TILT DOWN FEED L6 14DG MOTOR TILT UP FEED Z1 14BK/VT GROUND POWERTRAIN CONTROL MODULE C1 - GRAY 40 WAY CIRCUIT...
Page 833 2001 PT CRUISER 8Wa - 80 - 52 8W-80 CONNECTOR PINOUTS POWERTRAIN CONTROL MODULE C2 - GRAY 40 WAY CIRCUIT FUNCTION V37 20RD/LG SPEED CONTROL SWITCH SIGNAL K4 20BK/LB SENSOR GROUND K7 20OR 8V SUPPLY K10 20DB/OR STEERING PRESSURE SWITCH SENSE A14 18RD/WT FUSED B(+) Z11 18BK/WT...
Page 834 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 53 RADIATOR FAN MOTOR - BLACK 3 WAY CIRCUIT FUNCTION C23 12DG LOW SPEED RADIATOR FAN REALY OUTPUT Z1 12BK GROUND C25 12YL HIGH SPEED RADIATOR FAN RELAY OUTPUT RADIO C1 - GRAY 7 WAY CIRCUIT FUNCTION X55 18BR/DB (NORMAL BUILD)
Page 835 2001 PT CRUISER 8Wa - 80 - 54 8W-80 CONNECTOR PINOUTS REAR POWER OUTLET - BLACK 3 WAY CIRCUIT FUNCTION F30 16RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC) Z1 16BK GROUND REAR POWER WINDOW SWITCH (EARLY BUILD) - BLACK 8 WAY CIRCUIT FUNCTION Q14 14GY...
Page 836 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 55 REMOTE KEYLESS ENTRY ANTENNA (JAPAN) (NORMAL BUILD) - BLACK 2 WAY CIRCUIT FUNCTION X161 20WT ANTENNA COAX GROUND X164 20WT ANTENNA COAX CENTER REMOTE KEYLESS ENTRY MODULE - 26 WAY CIRCUIT FUNCTION L4 16VT/WT (EXCEPT BUILT-UP-EX-...
Page 837 2001 PT CRUISER 8Wa - 80 - 56 8W-80 CONNECTOR PINOUTS RIGHT BACK-UP LAMP - GRAY 2 WAY CIRCUIT FUNCTION L1 18VT/BK BACK-UP LAMP FEED Z1 18BK GROUND RIGHT FOG LAMP - GRAY 2 WAY CIRCUIT FUNCTION L39 18LB FOG LAMP SWITCH OUTPUT Z1 18BK GROUND RIGHT FRONT DOOR AJAR SWITCH (BASE) (NORMAL BUILD) - BLACK 2 WAY...
Page 838 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 57 RIGHT FRONT POWER WINDOW MOTOR - BLACK 2 WAY CIRCUIT FUNCTION Q22 14WT RIGHT FRONT WINDOW DRIVER DOWN Q12 14LB RIGHT FRONT WINDOW DRIVER UP RIGHT FRONT SIDE MARKER (BUILT-UP-EXPORT) - BLACK 2 WAY CIRCUIT FUNCTION L60 18TN...
Page 839 2001 PT CRUISER 8Wa - 80 - 58 8W-80 CONNECTOR PINOUTS RIGHT LAVALIER MODULE (BUILT-UP-EXPORT) - BLACK 4 WAY CIRCUIT FUNCTION L7 18BK/YL HEADLAMP SWITCH OUTPUT Z1 20BK (RHD) GROUND Z1 18BK (LHD) GROUND L13 20BR/YL HEADLAMP ADJUST SIGNAL L43 18VT FUSED LEFT LOW BEAM OUTPUT RIGHT LICENSE LAMP (BUILT-UP-EXPORT) - NATURAL 2 WAY CIRCUIT...
Page 840 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 59 RIGHT REAR DOOR POWER LOCK MOTOR - BLACK 3 WAY CIRCUIT FUNCTION P35 18OR/VT DOOR LOCK DRIVER P36 18PK/VT DOOR UNLOCK DRIVER RIGHT REAR FOG LAMP (RHD) - GRAY 2 WAY CIRCUIT FUNCTION L38 18BR/WT...
Page 841 2001 PT CRUISER 8Wa - 80 - 60 8W-80 CONNECTOR PINOUTS RIGHT REAR TURN SIGNAL LAMP - GRAY 2 WAY CIRCUIT FUNCTION L62 18BR/RD RIGHT REAR TURN SIGNAL Z1 18BK GROUND RIGHT REAR WHEEL SPEED SENSOR - BLACK 2 WAY CIRCUIT FUNCTION B2 20YL...
Page 842 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 61 RIGHT TAIL/STOP LAMP - BLACK 3 WAY CIRCUIT FUNCTION L50 18WT/TN BRAKE LAMP SWITCH OUTPUT L7 18BK/YL HEADLAMP SWITCH OUTPUT Z1 18BK GROUND RIGHT TURN SIGNAL INDICATOR - 2 WAY CIRCUIT FUNCTION L60 20TN...
Page 843 2001 PT CRUISER 8Wa - 80 - 62 8W-80 CONNECTOR PINOUTS SPEED CONTROL SERVO - BLACK 4 WAY CIRCUIT FUNCTION V36 20TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL V35 20LG/RD SPEED CONTROL VENT SOLENOID CONTROL V40 20DB/RD SPEED CONTROL BRAKE LAMP SWITCH OUTPUT Z1 20BK GROUND SUNROOF MOTOR - 2 WAY...
Page 844 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 63 TRANSMISSION CONTROL MODULE (A/T) - BLACK 60 WAY CIRCUIT FUNCTION T1 20LG/BK TRS T1 SENSE T3 20VT TRS T3 SENSE K24 20GY/BK CRANKSHAFT POSITION SENSOR SIGNAL D21 20PK SCI TRANSMIT A41 16YL FUSED IGNITION SWITCH OUTPUT (START) T9 18OR/BK...
Page 845 2001 PT CRUISER 8Wa - 80 - 64 8W-80 CONNECTOR PINOUTS TRANSMISSION CONTROL MODULE (A/T) - BLACK 60 WAY CIRCUIT FUNCTION T52 20RD/BK INPUT SPEED SENSOR SIGNAL Z14 16BK/YL GROUND T54 20VT/PK (LHD NORMAL BUILD) TRANSMISSION TEMPERATURE SENSOR SIGNAL T54 18VT/PK (RHD NORMAL BUILD) TRANSMISSION TEMPERATURE SENSOR SIGNAL T54 20VT/PK (EARLY BUILD) TRANSMISSION TEMPERATURE SENSOR SIGNAL...
Page 846 2001 PT CRUISER 8W-80 CONNECTOR PINOUTS 8Wa - 80 - 65 TRANSMISSION SOLENOID/PRESSURE SWITCH ASSEMBLY - BLACK 8 WAY CIRCUIT FUNCTION T47 18YL/BK 2-4 PRESSURE SWITCH SENSE T50 18DG LOW/REVERSE PRESSURE SWITCH SENSE T9 18OR/BK OVERDRIVE PRESSURE SWITCH SENSE T16 16RD TRANSMISSION CONTROL RELAY OUTPUT T59 18PK UNDERDRIVE SOLENOID CONTROL...
Page 847 2001 PT CRUISER...
Page 848 2001 PT CRUISER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 1 8W-90 CONNECTOR/GROUND LOCATIONS TABLE OF CONTENTS page CONNECTOR/GROUND LOCATIONS DESCRIPTION ......1 tor and ground index is provided.
Page 849 2001 PT CRUISER 8Wa - 90 - 2 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. C205 Upper Right Kick Panel 20, 22, 27 C206 Below Driver’s Seat C207 Right Side of Instrument Panel C208 Left Side of Instrument Panel C209 Right Rear of Instrument Panel C210...
Page 850: G300
2001 PT CRUISER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 3 CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Fuel Injector No.1 At Injector Fuel Injector No.2 At Injector Fuel Injector No.3 At Injector Fuel Injector No.4 At Injector Fuel Pump Module LT GY On Fuel Tank Fuse Block...
Page 851: Left Lavalier Module
2001 PT CRUISER 8Wa - 90 - 4 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Left Front Side Marker Left Front Wheel Opening Left Front Wheel Speed Sensor Left Front Wheel Opening Left High Beam Headlamp At Headlamp Assembly Left Instrument Panel Speaker Left Upper Instrument Panel...
Page 852: Remote Keyless Entry Antenna
2001 PT CRUISER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 5 CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Passenger Heated Seat Cushion Passenger Seat Passenger Heated Seat Module Passenger Seat Passenger Heated Seat Switch Passenger Seat Passenger Seat Belt Switch Lower Right B-Pillar Power Distribution Center Left Side of Engine Compartment...
Page 853 2001 PT CRUISER 8Wa - 90 - 6 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Right Rear Door Power Lock Motor Right Rear Door Right Rear Fog Lamp Right Side of Rear Fascia Right Rear Power Window Motor Right Rear Door Right Rear Power Window Switch Rear of Front Center Console...
Page 854 2001 PT CRUISER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 7 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 1 RIGHT FOG LAMP Fig. 2 LEFT FRONT LAMPS...
Page 855 2001 PT CRUISER 8Wa - 90 - 8 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 856 2001 PT CRUISER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 9 CONNECTOR/GROUND LOCATIONS (Continued)
Page 857 2001 PT CRUISER 8Wa - 90 - 10 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 858 2001 PT CRUISER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 11 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 6 LEFT SIDE ENGINE COMPARTMENT Fig. 7 RIGHT SIDE ENGINE COMPARTMENT...
Page 859 2001 PT CRUISER 8Wa - 90 - 12 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 8 RIGHT REAR ENGINE COMPARTMENT Fig. 9 RIGHT COWL PANEL...
Page 860 2001 PT CRUISER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 13 CONNECTOR/GROUND LOCATIONS (Continued)
Page 861 2001 PT CRUISER 8Wa - 90 - 14 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 862 2001 PT CRUISER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 15 CONNECTOR/GROUND LOCATIONS (Continued)
Page 863 2001 PT CRUISER 8Wa - 90 - 16 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 864 2001 PT CRUISER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 17 CONNECTOR/GROUND LOCATIONS (Continued)
Page 865 2001 PT CRUISER 8Wa - 90 - 18 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 15 REAR CENTER OF INSTRUMENT PANEL...
Page 866 2001 PT CRUISER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 19 CONNECTOR/GROUND LOCATIONS (Continued)
Page 867 2001 PT CRUISER 8Wa - 90 - 20 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 868 2001 PT CRUISER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 21 CONNECTOR/GROUND LOCATIONS (Continued)
Page 869 2001 PT CRUISER 8Wa - 90 - 22 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 870 2001 PT CRUISER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 23 CONNECTOR/GROUND LOCATIONS (Continued)
Page 871 2001 PT CRUISER 8Wa - 90 - 24 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 21 LEFT REAR OF INSTRUMENT PANEL...
Page 872 2001 PT CRUISER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 25 CONNECTOR/GROUND LOCATIONS (Continued)
Page 873 2001 PT CRUISER 8Wa - 90 - 26 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 23 LEFT FRONT BODY Fig. 24 LEFT SIDE BODY...
Page 874 2001 PT CRUISER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 27 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 25 RIGHT REAR BODY...
Page 875 2001 PT CRUISER 8Wa - 90 - 28 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 876 2001 PT CRUISER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 29 CONNECTOR/GROUND LOCATIONS (Continued)
Page 877 2001 PT CRUISER 8Wa - 90 - 30 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 878 2001 PT CRUISER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 31 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 29 LEFT SIDE CARGO AREA Fig. 30 LEFT REAR SPEAKER...
Page 879 2001 PT CRUISER 8Wa - 90 - 32 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 880 2001 PT CRUISER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 33 CONNECTOR/GROUND LOCATIONS (Continued)
Page 881 2001 PT CRUISER 8Wa - 90 - 34 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 33 CENTER HIGH MOUNTED STOP LAMP...
Page 882 2001 PT CRUISER 8W-90 CONNECTOR/GROUND LOCATIONS 8Wa - 90 - 35 CONNECTOR/GROUND LOCATIONS (Continued)
Page 883 2001 PT CRUISER...
Page 884 2001 PT CRUISER 8W-95 SPLICE LOCATIONS 8Wa - 95 - 1 8W-95 SPLICE LOCATIONS TABLE OF CONTENTS page SPLICE LOCATIONS DESCRIPTION ......1 index is provided.
Page 885 2001 PT CRUISER 8Wa - 95 - 2 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued) Splice Location Fig. S127 Near Brake Lamp Switch S128 Near T/O for Powertrain Control Module - C2 S129 (LHD) Near T/O for Powertrain Control Module - C2 S129 (IN PDC) (RHD) Inside of Power Distribution Center (PDC) S130...
Page 886 2001 PT CRUISER 8W-95 SPLICE LOCATIONS 8Wa - 95 - 3 SPLICE LOCATIONS (Continued) Splice Location Fig. S220 Near T/O for Brake Shift Interlock Solenoid S221 Near T/O for Passenger Airbag 7, 10 S222 Near T/O for Sentry Key Immobilizer Module S223 Near T/O for Ground G203 S224...
Page 887 2001 PT CRUISER 8Wa - 95 - 4 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued) Splice Location Fig. S303 Base of Right Rear Wheel Housing S304 Top of Left Rear Wheel Housing S305 Near T/O for Left Rear Door Ajar Switch S306 Near T/O for License Lamp S307...
Page 888 2001 PT CRUISER 8W-95 SPLICE LOCATIONS 8Wa - 95 - 5 SPLICE LOCATIONS (Continued)
Page 889 2001 PT CRUISER 8Wa - 95 - 6 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued)
Page 890 2001 PT CRUISER 8W-95 SPLICE LOCATIONS 8Wa - 95 - 7 SPLICE LOCATIONS (Continued)
Page 891 2001 PT CRUISER 8Wa - 95 - 8 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued)
Page 892 2001 PT CRUISER 8W-95 SPLICE LOCATIONS 8Wa - 95 - 9 SPLICE LOCATIONS (Continued)
Page 893 2001 PT CRUISER 8Wa - 95 - 10 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued)
Page 894 2001 PT CRUISER 8W-95 SPLICE LOCATIONS 8Wa - 95 - 11 SPLICE LOCATIONS (Continued)
Page 895 2001 PT CRUISER 8Wa - 95 - 12 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued) Fig. 8 CENTER AND RIGHT INSTRUMENT PANEL SPLICES Fig. 9 LEFT REAR INSTRUMENT PANEL SPLICES...
Page 896 2001 PT CRUISER 8W-95 SPLICE LOCATIONS 8Wa - 95 - 13 SPLICE LOCATIONS (Continued)
Page 897 2001 PT CRUISER 8Wa - 95 - 14 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued) Fig. 11 RIGHT REAR INSTRUMENT PANEL SPLICES...
Page 898 2001 PT CRUISER 8W-95 SPLICE LOCATIONS 8Wa - 95 - 15 SPLICE LOCATIONS (Continued)
Page 899 2001 PT CRUISER 8Wa - 95 - 16 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued)
Page 900 2001 PT CRUISER 8W-95 SPLICE LOCATIONS 8Wa - 95 - 17 SPLICE LOCATIONS (Continued)
Page 901 2001 PT CRUISER 8Wa - 95 - 18 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued)
Page 902 2001 PT CRUISER 8W-95 SPLICE LOCATIONS 8Wa - 95a - 19 SPLICE LOCATIONS (Continued)
Page 903 2001 PT CRUISER...
Page 904 ENGINE 9 - 1 ENGINE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION CAMSHAFT/CRANKSHAFT ENGINE ....... . . 2 SYNCHRONIZATION .
Page 905 9 - 2 ENGINE VALVE AND VALVE SPRING ....67 SPECIFICATIONS OIL PUMP......67 ENGINE OIL .
Page 906 ENGINE 9 - 3 DESCRIPTION AND OPERATION (Continued) Fig. 3 Balance Shafts and Carrier Assembly 1 – SPROCKET 7 – GEAR COVER 2 – TENSIONER 8 – CHAIN COVER 3 – CARRIER 9 – SPROCKET 4 – REAR COVER 10 – GUIDE 5 –...
Page 907 9 - 4 ENGINE DESCRIPTION AND OPERATION (Continued) per cylinder. The valves are arrange in two in-line banks. The intake valves face toward the front of the vehicle. The exhaust valves face the dash panel. The cylinder head incorporates powdered metal valve guides and seats.
Page 908 ENGINE 9 - 5 DESCRIPTION AND OPERATION (Continued) ance shaft carrier support leg. This passage directly supplies oil to the front bearings and internal machined passages in the shafts that routes oil from front to the rear shaft bearing journals. A vertical hole at the number five bulkhead routes pressurized oil through a restrictor (integral to the cylinder head gasket) up past a cylinder head bolt to an oil gallery...
Page 909 9 - 6 ENGINE DIAGNOSIS AND TESTING (Continued) Fig. 8 Engine Mounting—Right Side 1 – BOLT 7 – BOLT 2 – RIGHT FENDER 8 – LOWER TORQUE STRUT BRACKET 3 – UPPER TORQUE STRUT BRACKET 9 – BOLT 4 – NUT 10 –...
Page 910 ENGINE 9 - 7 DIAGNOSIS AND TESTING (Continued) ENGINE DIAGNOSIS—PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace as necessary. Refer to BATTERY. 2. Corroded or loose battery 2. Clean and tighten battery connections.
Page 911 9 - 8 ENGINE DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION ENGINE MISSES ON 1. Dirty or incorrectly gapped spark 1. Clean spark plugs and set gap. ACCELERATION plugs. Refer to IGNITION SYSTEM. 2. Contamination in Fuel System. 2. Clean fuel system and replace fuel filter.
Page 912 ENGINE 9 - 9 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level. 2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring. 3.
Page 913 9 - 10 ENGINE DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL CONSUMPTION OR SPARK 1. PCV system malfunction. 1. Check system and repair as PLUGS FOULED necessary. Refer to EMISSION CONTROL SYSTEMS. 2. Worn, scuffed or broken rings. 2.
Page 914 ENGINE 9 - 11 DIAGNOSIS AND TESTING (Continued) (4) Disconnect coil wire from distributor and Calibrate the tester according to the manufactur- secure to good ground to prevent a spark from start- er’s instructions. The shop air source for testing ing a fire (Conventional Ignition System).
Page 915 9 - 12 ENGINE DIAGNOSIS AND TESTING (Continued) • If a cylinder is leaking combustion pressure into (3) Using a black light, inspect the entire engine the water jacket, the tester pointer will pulsate with for fluorescent dye, particularly at the suspected area every combustion stroke of the cylinder.
Page 916 ENGINE 9 - 13 DIAGNOSIS AND TESTING (Continued) (2) Raise the vehicle. Checking the oil while the vehicle is on level (3) Remove torque converter or clutch housing ground will improve the accuracy of the oil level cover and inspect rear of block for evidence of oil. reading.
Page 917 9 - 14 ENGINE SERVICE PROCEDURES (Continued) Fig. 10 Engine Oil Dipstick and Fill Locations 1 – ENGINE OIL FILL 3 – ENGINE OIL DIPSTICK 2 – COOLANT RECOVERY BOTTLE 4 – COOLANT PRESSURE CAP Fig. 11 Engine Oil Dipstick OIL FILTER SPECIFICATION All engines are equipped with a high quality full- flow, disposable type oil filter.
Page 918 ENGINE 9 - 15 SERVICE PROCEDURES (Continued) place gasket material unless specified. Bead size, vent corrosion. Mopar Gasket Sealant is available in continuity, and location are of great importance. Too a 13 oz. aerosol can or 4oz./16 oz. can w/applicator. thin a bead can result in leakage while too much can FORM-IN-PLACE GASKET AND SEALER result in spill-over which can break off and obstruct...
Page 919 9 - 16 ENGINE SERVICE PROCEDURES (Continued) CAUTION: Excessive pressure high C-3501 or equivalent, equipped with 280 grit stones, (beyond the recommended speed), can damage the if the cylinder bore is straight and round. 20–60 strokes depending on the bore condition, will be suf- sealing surfaces.
Page 920 ENGINE 9 - 17 SERVICE PROCEDURES (Continued) should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line shown in (Fig. 15). Refer to for Engine Specifications. Correct piston to bore clearance must be established in order to assure quiet and economical operation.
Page 921 9 - 18 ENGINE SERVICE PROCEDURES (Continued) Fig. 21 Piston Ring End Gap Position Fig. 19 Piston Ring Installation 1 – GAP OF LOWER SIDE RAIL 1 – NO. 1 PISTON RING 2 – NO. 1 RING GAP 2 – NO. 2 PISTON RING 3 –...
Page 922 ENGINE 9 - 19 SERVICE PROCEDURES (Continued) One scale is in inches, the other is a metric CRANKSHAFT MAIN BEARINGS scale. If the bearing clearance exceeds wear The crankshaft is supported in five main bearings. limit specification, replace the bearing. All upper and lower bearing shells in the crankcase have oil grooves.
Page 923 9 - 20 ENGINE SERVICE PROCEDURES (Continued) (6) Remove the bedplate and compare the width of (2) Make certain oil holes in block line up with oil the flattened Plastigage (Fig. 25) with the metric holes in bearings. Bearing tabs must seat in the scale provided on the package.
Page 924 ENGINE 9 - 21 SERVICE PROCEDURES (Continued) (6) Before installing bolts, lubricate the threads (4) Move crankshaft all the way to the front and with clean engine oil, wipe off any excess oil. read the dial indicator. Refer to Engine Specifications (7) Install main bearing bedplate to engine block for end play specification.
Page 925 9 - 22 ENGINE SERVICE PROCEDURES (Continued) (1) Perform camshaft and crankshaft synchroniza- INSTALLATION tion procedure as follows: (1) Position the upper torque strut into mounting a. Connect the DRBIII scan tool to the data link location. (diagnostic) connector. This connector is located in (2) Move torque strut aside (towards right fender) the passenger compartment;...
Page 926 ENGINE 9 - 23 REMOVAL AND INSTALLATION (Continued) (3) Install pencil strut and tighten nuts to 58 N·m (43 ft. lbs.) (Fig. 33). (4) Install accessory belt splash shield (Fig. 32) and lower vehicle TORQUE STRUT ADJUSTMENT The upper and lower torque struts need to be adjusted together to assure proper engine mount load balance and engine positioning.
Page 927 9 - 24 ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 35 Engine Position Measurement (5) With the engine held at the proper position, tighten both the upper and lower torque strut bolts to 118 N·m (87 ft. lbs.) (Fig. 31). (6) Remove the floor jack. (7) Install pencil strut and tighten nuts to 58 N·m (43 ft.
Page 928 ENGINE 9 - 25 REMOVAL AND INSTALLATION (Continued) ENGINE MOUNT—RIGHT b. Align the four holes in the mount with the mat- ing holes in the rail such that the holes are concen- tric (frame rail holes centered in the mount holes). REMOVAL c.
Page 929 9 - 26 ENGINE REMOVAL AND INSTALLATION (Continued) (2) Remove bolts attaching bending strut to engine and transaxle (Fig. 41). Remove strut. (3) Remove bolts attaching collar and clutch slave cylinder to transaxle (Fig. 41). (4) Remove remaining bolts attaching collar to oil pan and transaxle (Fig.
Page 930 ENGINE 9 - 27 REMOVAL AND INSTALLATION (Continued) • Step 5: Position power steering hose support bracket and install the remaining collar to oil pan bolt (6) hand tight only. • Step 6: Final torque all bolts in sequence shown in (Fig.
Page 931 9 - 28 ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 45 Clutch Hydraulic Line to Slave Cylinder— (Manual Transaxle Equipped) 1 – SLAVE CYLINDER 2 – HYDRAULIC TUBE Fig. 44 PDC Bracket Attaching Bolts 1 – PDC 2 – PDC BRACKET BOLTS 3 –...
Page 932 ENGINE 9 - 29 REMOVAL AND INSTALLATION (Continued) Fig. 49 Power Steering Fluid Return Hose 1 – RESERVOIR 2 – CLAMP Fig. 47 Exhaust System To Manifold Connection 3 – POWER STEERING RETURN LINE 1 – GASKET 2 – CATALYTIC CONVERTER WARNING: Safety straps MUST be used.
Page 933 9 - 30 ENGINE REMOVAL AND INSTALLATION (Continued) (Fig. 50) and (Fig. 51). Tighten bolts to 118 N·m (87 ft. lbs.). (3) Install upper torque strut. Refer to procedure in this section. (4) Remove safety straps from engine/transaxle assembly. Slowly raise vehicle enough to remove the engine dolly and cradle.
Page 934 ENGINE 9 - 31 REMOVAL AND INSTALLATION (Continued) (17) Connect power steering fluid return hose to reservoir (Fig. 49). Fill power steering fluid reservoir to proper level. (18) Manual Transmission: Connect clutch hydraulic line (Fig. 45), electrical connector and shift linkages.
Page 935 9 - 32 ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 55 Idle Air Control (IAC) Motor and Throttle Fig. 57 MAP Sensor Position Sensor (TPS) Wiring Connectors 1 – MAP SENSOR 1 – IAC 2 – PCM 3 – TPS Fig. 58 Throttle Body Support Bracket and PCV Hose 1 –...
Page 936 ENGINE 9 - 33 REMOVAL AND INSTALLATION (Continued) Fig. 61 Intake Manifold Tightening Sequence Fig. 59 EGR Tube 1 – BOLTS 2 – EGR TUBE Fig. 62 Upper Intake Manifold to EGR Tube 1 – INTAKE MANIFOLD 2 – EGR TUBE 3 –...
Page 937 9 - 34 ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 63 Engine Cover 1 – BALL STUDS (1) Perform fuel system pressure release procedure Fig. 64 Dipstick Tube before attempting any repairs. Refer to FUEL 1 – DIPSTICK TUBE SYSTEM for procedure. 2 –...
Page 938 ENGINE 9 - 35 REMOVAL AND INSTALLATION (Continued) (4) If removed, install the fuel rail assembly to intake manifold. Tighten screws to 23 N·m (200 in. lbs.). (5) Connect fuel injector wiring harness. (6) Inspect quick connect fittings for damage, replace if necessary.
Page 939 9 - 36 ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 71 Heat Shield—Engine Wiring 1 – HEAT SHIELD Fig. 69 Exhaust Manifold Support Bracket 2 – NUT 3 – NUT Fig. 70 Exhaust Manifold To Pipe Connection 1 – GASKET Fig. 72 Exhaust Manifold Heat Shields 2 –...
Page 940 ENGINE 9 - 37 REMOVAL AND INSTALLATION (Continued) Fig. 73 Exhaust Manifold Fig. 75 Crankshaft Damper—Installation (3) Remove damper by using Special Tool 1026 and 1 – SPECIAL TOOL 6792 Insert 6827–A (Fig. 74). TIMING BELT COVER FRONT COVER—UPPER REMOVAL (1) Remove upper torque strut attaching bolts and set strut aside.
Page 941 9 - 38 ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 76 Front Timing Belt Covers Fig. 77 Engine Support Bracket 1 – UPPER COVER FASTENERS 1 – ENGINE SUPPORT BRACKET 2 – LOWER COVER FASTENERS 2 – BOLTS (10) Discharge A/C system and disconnect A/C (3) Lower engine into mounting position and lines at coupling block.
Page 942 ENGINE 9 - 39 REMOVAL AND INSTALLATION (Continued) REAR COVER REMOVAL (1) Remove timing belt. Refer to procedure in this section. (2) Remove timing belt idler pulley. (3) Remove camshaft sprockets (Fig. 79). (4) Remove rear timing belt fasteners and remove cover from engine (Fig.
Page 943 9 - 40 ENGINE REMOVAL AND INSTALLATION (Continued) (20) Remove upper timing belt cover fasteners and remove cover (Fig. 80). (21) Remove lower timing belt cover fasteners and remove cover (Fig. 80). Fig. 81 Engine Support Bracket 1 – ENGINE SUPPORT BRACKET 2 –...
Page 944 ENGINE 9 - 41 REMOVAL AND INSTALLATION (Continued) Fig. 83 Locking Timing Belt Tensioner 1 – 1/8 OR 3mm ALLEN WRENCH 2 – BELT TENSIONER 3 – 6mm ALLEN WRENCH Fig. 82 Crankshaft and Camshaft Timing 1 – CAMSHAFT TIMING MARKS 2 –...
Page 945 9 - 42 ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 86 Crankshaft and Camshaft Timing 1 – CAMSHAFT TIMING MARKS 2 – CRANKSHAFT TDC MARKS 3 – TRAILING EDGE OF SPROCKET TOOTH (3) Hold camshaft sprocket with Special Tool 6847 Fig. 85 Timing Belt—Installation while removing bolt (Fig.
Page 946 ENGINE 9 - 43 REMOVAL AND INSTALLATION (Continued) Fig. 89 Timing Belt Tensioner Assembly 1 – BOLT 2 – TENSIONER ASSEMBLY Fig. 88 Rear Timing Belt Cover Fasteners 3 – BOLT-INSTALL FOR PROPER ALIGNMENT 1 – REAR COVER TO CYLINDER HEAD FASTENERS 2 –...
Page 947 9 - 44 ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 92 Spark Plug Well Seals Fig. 90 PCV and Make-up Air Hoses 1 – PCV HOSE 2 – MAKE-UP AIR HOSE Fig. 91 Cylinder Head Cover Gasket and Spark Plug Fig. 93 Cylinder Head Cover Bolt Seals Well Seals (3) Apply Mopar Engine RTV GEN II at the cam- 1 –...
Page 948 ENGINE 9 - 45 REMOVAL AND INSTALLATION (Continued) (8) Install upper intake manifold. Refer to proce- dure in this section. CAMSHAFT REMOVAL (1) Remove cylinder head cover. Refer to procedure in this section. (2) Remove camshaft position sensor and camshaft target magnet.
Page 949 9 - 46 ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 99 Camshaft Bearing Cap Tightening Sequence Fig. 97 Camshaft Bearing Cap—Removal 1 – REMOVE OUTSIDE BEARING CAPS FIRST Fig. 100 Camshaft Bearing Cap Sealing 1 – 1.5 mm (.060 in.) DIAMETER BEAD OF MOPAR GASKET MAKER (6) Install camshaft target magnet and camshaft Fig.
Page 950 ENGINE 9 - 47 REMOVAL AND INSTALLATION (Continued) Fig. 103 Camshaft Seal Installation—Typical 1 – SPECIAL TOOL MD 998306 Fig. 101 Camshaft Sprocket—Removal/Installation (4) Install camshaft sprockets. Hold sprockets with 1 – SPECIAL TOOL 6847 Special Tool 6847. Tighten the center bolt to 101 N·m (75 ft.
Page 951 9 - 48 ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 105 Hydraulic Lash Adjuster INSTALLATION (1) Install hydraulic lash adjuster (Fig. 105). Fig. 104 Camshaft Follower—Removal/Installation Ensure the adjusters are at least partially full of 1 – SPECIAL TOOL 8215 engine oil. This is indicated by little or no plunger 2 –...
Page 952 ENGINE 9 - 49 REMOVAL AND INSTALLATION (Continued) (7) Remove fastener attaching dipstick tube to lower intake manifold (Fig. 108). Fig. 106 Valve Spring—Removal/Installation 1 – VALVE SPRING COMPRESSOR MD 998772A 2 – AIR HOSE Fig. 108 Dipstick Tube 1 – DIPSTICK TUBE 2 –...
Page 953 9 - 50 ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION NOTE: The Cylinder head bolts should be exam- ined BEFORE reuse. If the threads are necked down, the bolts should be replaced (Fig. 111). Necking can be checked by holding a scale or straight edge against the threads.
Page 954 ENGINE 9 - 51 REMOVAL AND INSTALLATION (Continued) CAUTION: Do not use a torque wrench for the fol- (23) Perform camshaft/crankshaft synchronization lowing step. procedure. Refer to procedure in this section. • Fourth Turn an additional 1/4 Turn, VALVE AND VALVE SPRING REMOVAL (1) With cylinder head removed, compress valve springs using a universal valve spring compressor.
Page 955 9 - 52 ENGINE REMOVAL AND INSTALLATION (Continued) (4) Check the valve spring installed height B after refacing the valve and seat (Fig. 115). Make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 38.75 mm (1.525 in.), install a 0.762 mm (0.030 in.) spacer under the valve spring seat to bring spring height back within specification.
Page 956 ENGINE 9 - 53 REMOVAL AND INSTALLATION (Continued) Fig. 118 Chain Cover, Guide and Tensioner Fig. 119 Drive Chain and Sprockets 1 – STUD 1 – NICKEL PLATED LINK AND MARK 2 – TENSIONER (ADJUSTER) 2 – GEAR/SPROCKET SCREWS 3 – GEAR COVER 3 –...
Page 957 9 - 54 ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 121 Balance Shaft(s)—Removal/Installation 1 – SPROCKET 7 – GEAR COVER 2 – TENSIONER 8 – CHAIN COVER 3 – CARRIER 9 – SPROCKET 4 – REAR COVER 10 – GUIDE 5 – BALANCE SHAFTS 11 –...
Page 958 ENGINE 9 - 55 REMOVAL AND INSTALLATION (Continued) NOTE: The lower plated link is 8 links from the upper link. (9) With balance shaft keyways pointing up (12 o’clock) slide the balance shaft sprocket onto the nose of the balance shaft. The balance shaft may have to be pushed in slightly to allow for clearance.
Page 959 9 - 56 ENGINE REMOVAL AND INSTALLATION (Continued) (b) Position guide on double ended stud making CAUTION: Do not nick shaft seal surface or seal sure tab on the guide fits into slot on the gear bore. cover. Install and tighten nut/washer assembly to (4) Using Tool 6771 to remove front crankshaft oil 12 N·m (105 in.
Page 960 ENGINE 9 - 57 REMOVAL AND INSTALLATION (Continued) Fig. 129 Front Crankshaft Oil Seal—Removal 1 – SPECIAL TOOL 6771 2 – REAR TIMING BELT COVER (4) Install timing belt. Refer to procedure in this section. (5) Install crankshaft damper (Fig. 132). Use thrust bearing/washer and 12M 1.75 x 150 mm bolt from Special Tool 6792.
Page 961 9 - 58 ENGINE REMOVAL AND INSTALLATION (Continued) (1) Place Special Tool 6926-1 Seal Guide on crank- shaft (Fig. 134). (2) Position seal over guide tool (Fig. 134). Guide tool should remain on crankshaft during installation of seal. Ensure that the lip of the seal is facing towards the crankcase during installation.
Page 962 ENGINE 9 - 59 REMOVAL AND INSTALLATION (Continued) Fig. 135 Crankshaft Seal and Special Tools 6926-2 & C-4171 1 – SPECIAL TOOL 6926–1 PILOT 2 – SEAL 3 – SPECIAL TOOL 6926–2 INSTALLER 4 – SPECIAL TOOL C-4171 Fig. 136 Rear Crankshaft Seal—Installation 1 –...
Page 963 9 - 60 ENGINE REMOVAL AND INSTALLATION (Continued) (5) Install lower main bearings into main bearing cap/bedplate. Make certain the bearing tabs are seated into the bedplate slots. Install the main bear- ing/bedplate into engine block. (6) Before installing the bolts the threads should be oiled with clean engine oil, wipe off any excess oil.
Page 964 ENGINE 9 - 61 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) For proper piston ring seating, deglaze/hone the cylinder bore. Refer to procedure in this section. (2) Before installing pistons and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap.
Page 965 9 - 62 ENGINE REMOVAL AND INSTALLATION (Continued) (6) Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston assembly into cylinder bore and guide rod over the crankshaft journal. (7) Tap the piston down in cylinder bore, using a hammer handle.
Page 966 ENGINE 9 - 63 REMOVAL AND INSTALLATION (Continued) Fig. 147 Oil Pump 1 – BOLTS 2 – BOLTS 3 – OIL PUMP Fig. 149 Front Crankshaft Seal—Installation 1 – PROTECTOR 2 – SEAL 3 – SPECIAL TOOL 6780 Fig. 148 Oil Pump Sealing 1 –...
Page 967 9 - 64 ENGINE REMOVAL AND INSTALLATION (Continued) (11) Install timing belt. Refer to procedure in this section. OIL FILTER REMOVAL CAUTION: When servicing the oil filter avoid deforming the filter can by installing the remove/in- stall tool band strap against the can to base lock seam.
Page 968 ENGINE 9 - 65 REMOVAL AND INSTALLATION (Continued) INSTALLATION It is not necessary to wait for curing of the sealant. The cooling system can be refilled and the vehicle (1) Install oil pressure switch and connect electri- placed in service immediately. cal connector (Fig.
Page 969 9 - 66 ENGINE DISASSEMBLY AND ASSEMBLY (Continued) (2) Inspect manifolds for cracks or distortion. Replace manifold as necessary. CYLINDER HEAD CLEANING Remove all gasket material from cylinder head and block. Be careful not to gouge or scratch the alumi- num head sealing surface.
Page 970 ENGINE 9 - 67 CLEANING AND INSPECTION (Continued) INSPECTION (1) Cylinder head must be flat within 0.1 mm (0.004 in.) (Fig. 158). (2) Inspect camshaft bearing journals for scoring. Fig. 160 Valve Guide Height 1 – VALVE GUIDE 2 – 13.25 - 13.75 MM (.521 -.541 IN.) 3 –...
Page 971 9 - 68 ENGINE CLEANING AND INSPECTION (Continued) (3) Measure thickness and diameter of outer rotor. mm (0.015 in.) or more, replace housing only if outer If outer rotor thickness measures 9.40 mm (0.370 in.) rotor is in specification. or less (Fig. 163), or if the diameter is 79.95 mm (2) Install inner rotor into pump housing.
Page 972 ENGINE 9 - 69 CLEANING AND INSPECTION (Continued) Fig. 167 Measuring Clearance Over Rotors 1 – STRAIGHT EDGE Fig. 165 Measuring Outer Rotor Clearance in 2 – FEELER GAUGE Housing 1 – FEELER GAUGE ing should not exceed.305 mm (.012 inch) under the 2 –...
Page 973 9 - 70 ENGINE CLEANING AND INSPECTION (Continued) CYLINDER BLOCK CLEANING Clean cylinder block thoroughly. INSPECTION Fig. 170 Cam Follower Assembly 1 – LASH ADJUSTER POCKET 2 – OIL SQUIRT HOLE 3 – ROLLER strut bolt(s) is loosened the following procedure must be performed.
Page 974 ENGINE 9 - 71 ADJUSTMENTS (Continued) Fig. 171 Torque Strut Bolts 1 – BOLT 7 – BOLT 2 – RIGHT FENDER 8 – LOWER TORQUE STRUT BRACKET 3 – UPPER TORQUE STRUT BRACKET 9 – BOLT 4 – NUT 10 – LOWER TORQUE STRUT 5 –...
Page 975 9 - 72 ENGINE ADJUSTMENTS (Continued) Fig. 175 Engine Oil Container Standard Notations SAE VISCOSITY An SAE viscosity grade is used to specify the vis- cosity of engine oil. Use only engine oils with multi- ple viscosities such as 5W-30 or 10W-30. These are specified with a dual SAE viscosity grade which indi- Fig.
Page 976 ENGINE 9 - 73 SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Max. Variation Between Ring Gap—2nd 0.23–0.48 mm Cylinders Compression Ring (0.009–0.018 in.) Cylinder Block Wear Limit 0.8 mm Cylinder Bore Diameter 87.4924–87.5076 mm (0.031 in.) (3.4446–3.4452 in.) Ring Gap—Oil Control 0.25–0.64 mm Steel Rails Out-of-Round (Max.)
Page 977 9 - 74 ENGINE SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION End Play 0.09–0.24 mm Valve Seat (0.0035–0.0094 in.) Angle 44.5–45° Wear Limit 0.37 mm Seat Diameter—Intake 34.37–34.63 mm (0.015 in.) (1.353–1.363 in.) Main Bearing Diametrical 0.018–0.058 mm Seat Diameter—Exhaust 27.06–27.32 mm Clearance (0.0007–0.0023 in.) (1.065–1.075 in.)
Page 978 ENGINE 9 - 75 SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Service Limit 0.95 mm (0.001 in.) (1/32 in.) Inner Rotor Thickness 9.40 mm (Min.) Exhaust 0.985–1.315 mm (0.370 in.) (0.038–0.051 in.) Outer Rotor Thickness 9.40 mm Service Limit 1.05 mm (Min.) (3/64 in.) (0.370 in.)
Page 979 9 - 76 ENGINE 2001 PT Service Manual SPECIFICATIONS (Continued) Publication No. 81-370-1111 TSB 26-10-01 October, 2001 SPECIAL TOOLS DESCRIPTION N·m Lbs. Lbs. 2.4L ENGINE Cylinder Head—Bolts Refer to Procedure Cylinder Head Cover— — Bolts Flex Plate to Crankshaft— — Bolts Engine Support —...
Page 980 ENGINE 9 - 77 SPECIAL TOOLS (Continued) Crankshaft Damper Installer 6792 Post Kit Engine Cradle 6848 Valve Spring Compressor 8215 Clutch Line Disconnect 6638-A Camshaft Sprocket Holder 6847 Adaptor 8436 Camshaft Seal Remover C-4679-A Valve Spring Compressor MD-998772-A Camshaft Seal Installer MD-998306...
Page 981 9 - 78 ENGINE SPECIAL TOOLS (Continued) Valve Spring Compressor Adapter 6779 Crankshaft Front Seal Remover 6771 Cylinder Bore Gage C-119 Oil Pressure Gage C-3292 Adaptor 8406 Connecting Rod Guides 8189 Rear Crankshaft Seal Guide and Installer 6926-1 and 6926-2 Crankshaft Sprocket Remover 6793 Balance Shaft Sprocket Installer 6052 Crankshaft Sprocket Remover Insert C-4685-C2...
Page 982 ENGINE 9 - 79 SPECIAL TOOLS (Continued) Cooling System Tester 7700 Post Adapter 8130 Front Crankshaft Oil Seal Installer 6780 Cylinder Compression Pressure Adaptor 8116 Combustion Leak Tester C-3685-A DRB III with PEP Module OT-CH6010A...
Page 984 2001 PT CRUISER ENGINE 9a - 1 ENGINE TABLE OF CONTENTS page 2.0L DOHC ENGINE ......1 2.0L DOHC ENGINE TABLE OF CONTENTS page...
Page 985 2001 PT CRUISER 9a - 2 2.0L DOHC ENGINE EXHAUST MANIFOLD ..... 63 SPECIFICATIONS CYLINDER HEAD......63 ENGINE .
Page 986 2001 PT CRUISER 2.0L DOHC ENGINE 9a - 3 DESCRIPTION AND OPERATION (Continued) DESCRIPTION CRANKSHAFT The 2.0 Liter (122 cu. in.) in-line four cylinder DESCRIPTION engine is a dual over-head camshaft with hydraulic lifters and four valves per cylinder design (Fig. 1). The crankshaft is made of nodular cast iron and The engine does not have provisions for a free wheel- includes five main bearing journals and four connect-...
Page 987 2001 PT CRUISER 9a - 4 2.0L DOHC ENGINE DESCRIPTION AND OPERATION (Continued) assembly. The pistons and connecting rods are ser- viced as an assembly OPERATION The piston and connecting rod is the link between the combustion force to the crankshaft. CYLINDER HEAD DESCRIPTION The cross flow designed, aluminum cylinder head...
Page 988 2001 PT CRUISER 2.0L DOHC ENGINE 9a - 5 DESCRIPTION AND OPERATION (Continued) OPERATION The exhaust manifold collects the exhaust gasses exiting the combustion chambers. Then it channels the exhaust gasses to the exhaust pipe attached to the manifold. ENGINE LUBRICATION DESCRIPTION The lubrication system is a full-flow filtration, pressure feed type.
Page 989 2001 PT CRUISER 9a - 6 2.0L DOHC ENGINE DESCRIPTION AND OPERATION (Continued) Fig. 8 Engine Lubrication Components 1 – O-RING 7 – O-RING 2 – OIL FILTER ADAPTER 8 – OIL PUMP BODY 3 – OIL PAN GASKET 9 – FILTER 4 –...
Page 990 2001 PT CRUISER 2.0L DOHC ENGINE 9a - 7 DESCRIPTION AND OPERATION (Continued) ENGINE MOUNT DESCRIPTION The powertrain mounting system consist of a four- point system utilizing two load-carrying mounts and two torque struts. The load-carrying mounts are located on each frame rail. The right mount is a hydro-elastic mount and left mount is a conventional elastomeric isolator.
Page 991 2001 PT CRUISER 9a - 8 2.0L DOHC ENGINE DESCRIPTION AND OPERATION (Continued) Fig. 10 Powertrain Mounting 1 – RIGHT FENDER 7 – BOLTS 2 – UPPER TORQUE STRUT BRACKET 8 – BOLTS 3 – NUT 9 – RIGHT ENGINE MOUNT 4 –...
Page 992 2001 PT CRUISER 2.0L DOHC ENGINE 9a - 9 DIAGNOSIS AND TESTING (Continued) ENGINE DIAGNOSIS—PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace as necessary. Refer to BATTERY. 2. Corroded or loose battery 2.
Page 993 2001 PT CRUISER 9a - 10 2.0L DOHC ENGINE DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION ENGINE MISSES ON 1. Dirty or incorrectly gapped spark 1. Clean spark plugs and set gap. ACCELERATION plugs. Refer to IGNITION SYSTEM. 2. Contamination in Fuel System. 2.
Page 994 2001 PT CRUISER 2.0L DOHC ENGINE 9a - 11 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level. 2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring.
Page 995 2001 PT CRUISER 9a - 12 2.0L DOHC ENGINE DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL CONSUMPTION OR SPARK 1. PCV system malfunction. 1. Check system and repair as PLUGS FOULED necessary. Refer to EMISSION CONTROL SYSTEMS. 2. Worn, scuffed or broken rings. 2.
Page 996 2001 PT CRUISER 2.0L DOHC ENGINE 9a - 13 DIAGNOSIS AND TESTING (Continued) (4) Disconnect coil wire from distributor and Calibrate the tester according to the manufactur- secure to good ground to prevent a spark from start- er’s instructions. The shop air source for testing ing a fire (Conventional Ignition System).
Page 997 2001 PT CRUISER 9a - 14 2.0L DOHC ENGINE DIAGNOSIS AND TESTING (Continued) • If a cylinder is leaking combustion pressure into (3) Using a black light, inspect the entire engine the water jacket, the tester pointer will pulsate with for fluorescent dye, particularly at the suspected area every combustion stroke of the cylinder.
Page 998 2001 PT CRUISER 2.0L DOHC ENGINE 9a - 15 DIAGNOSIS AND TESTING (Continued) (2) Raise the vehicle. SERVICE PROCEDURES (3) Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. ENGINE OIL LEVEL CHECK Use a black light to check for the oil leak.
Page 999 2001 PT CRUISER 9a - 16 2.0L DOHC ENGINE SERVICE PROCEDURES (Continued) Fig. 11 Dipstick and Engine Oil Fill Locations—2.0L 1 – ENGINE OIL FILL 3 – ENGINE OIL DIPSTICK 2 – COOLANT RECOVERY BOTTLE 4 – COOLANT PRESSURE CAP Fig.
Page 1000 2001 PT CRUISER 2.0L DOHC ENGINE 9a - 17 SERVICE PROCEDURES (Continued) TO CHANGE ENGINE OIL tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect Run engine until achieving normal operating tem- the package for the expiration date before use.
Page 1001 2001 PT CRUISER 9a - 18 2.0L DOHC ENGINE SERVICE PROCEDURES (Continued) over both surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can w/applicator can be brushed on evenly over the sealing surfaces.
Page 1002 2001 PT CRUISER 2.0L DOHC ENGINE 9a - 19 SERVICE PROCEDURES (Continued) CONNECTING ROD BEARING CLEARANCE ENGINE WITH 4 MAIN BEARING • When checking #1 main bearing shim # 2 main Engine connecting rod bearing clearances can be bearing. determined by use of Plastigage or equivalent. The •...
Page 1003 2001 PT CRUISER 9a - 20 2.0L DOHC ENGINE SERVICE PROCEDURES (Continued) will clean up a bore and maintain the required lim- its. (2) Deglazing of the cylinder walls may be done using a cylinder surfacing hone, recommended tool C-3501 or equivalent, equipped with 280 grit stones, if the cylinder bore is straight and round.
Page 1004 2001 PT CRUISER 2.0L DOHC ENGINE 9a - 21 SERVICE PROCEDURES (Continued) PISTON RING—FITTING following is the recommended procedure for the use of Plastigage: (1) Wipe cylinder bore clean. Insert ring and push (1) Rotate the crankshaft until the connecting rod down with piston to ensure it is square in bore.
Page 1005 2001 PT CRUISER 9a - 22 2.0L DOHC ENGINE SERVICE PROCEDURES (Continued) same width. This band shows the amount of clear- ance in thousandths of a millimeter. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Refer to Engine Specifications.
Page 1006 2001 PT CRUISER 2.0L DOHC ENGINE 9a - 23 SERVICE PROCEDURES (Continued) REPAIR OF DAMAGED OR WORN THREADS LOWER TORQUE STRUT Damaged or worn threads (including aluminum REMOVAL head spark plug threads) can be repaired. Essen- (1) Raise vehicle on hoist. tially, this repair consists of drilling out worn or (2) Remove right side splash shield.
Page 1007 2001 PT CRUISER 9a - 24 2.0L DOHC ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 27 Torque Struts—Upper and Lower 1 – RIGHT FENDER 7 – BOLTS 2 – UPPER TORQUE STRUT BRACKET 8 – BOLTS 3 – NUT 9 – RIGHT ENGINE MOUNT 4 –...
Page 1008 2001 PT CRUISER 2.0L DOHC ENGINE 9a - 25 REMOVAL AND INSTALLATION (Continued) Fig. 30 Left Mount 1 – BOLT 2 – LEFT MOUNT Fig. 28 Floor Jack Positioning 3 – TRANSAXLE 1 – WOOD BLOCK 4 – BOLT 2 – FLOOR JACK Fig.
Page 1009 2001 PT CRUISER 9a - 26 2.0L DOHC ENGINE REMOVAL AND INSTALLATION (Continued) STRUCTURAL COLLAR STRUCTURAL COLLAR—AUTOMATIC TRANSAXLE EQUIPPED REMOVAL (1) Raise vehicle on hoist. (2) Remove bolts attaching bending strut to engine and transaxle (Fig. 32). (3) Remove bolts attaching collar and strut to engine, oil pan, and transaxle (Fig.
Page 1010 2001 PT CRUISER 2.0L DOHC ENGINE 9a - 27 REMOVAL AND INSTALLATION (Continued) Fig. 34 Structural Collar and Bending Strut— (Manual Transaxle Equipped) • Step 2: Position power steering hose support Fig. 35 Battery—Removal/Installation bracket (Fig. 34) and install collar to oil pan bolt (2), 1 –...
Page 1011 2001 PT CRUISER 9a - 28 2.0L DOHC ENGINE REMOVAL AND INSTALLATION (Continued) (10) Disconnect positive cable from Power Distri- (22) Disconnect automatic transmission cooler bution Center (PDC) and ground wire from vehicle lines and plug, if equipped. body. Remove bolts attaching PDC and set aside (Fig. (23) Disconnect electrical connector...
Page 1012 2001 PT CRUISER 2.0L DOHC ENGINE 9a - 29 REMOVAL AND INSTALLATION (Continued) Fig. 39 Disconnecting Clutch Hydraulic Line— (Manual Transaxle Equipped) Fig. 41 Power Steering Fluid Pressure Hose 1 – QUICK CONNECT FITTING 1 – STEERING GEAR 2 – TOOL 6638A 2 –...
Page 1013 2001 PT CRUISER 9a - 30 2.0L DOHC ENGINE REMOVAL AND INSTALLATION (Continued) (44) Raise vehicle enough to determine if straps bolts at the right and left engine/transaxle mounts are secure enough to hold cradle assembly to engine. (Fig. 43) and (Fig. 44). Tighten bolts to 118 N·m (87 (45) Lower vehicle so weight of the engine and ft.
Page 1014 2001 PT CRUISER 2.0L DOHC ENGINE 9a - 31 REMOVAL AND INSTALLATION (Continued) Fig. 45 Positioning Engine Cradle Support Post 1 – POST LOCATING HOLES IN BLOCK 5 – FLOOR JACK 2 – POST POSITIONED UNDER BRACKET 6 – SPECIAL TOOL 6848 3 –...
Page 1015 2001 PT CRUISER 9a - 32 2.0L DOHC ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 47 Idle Air Control (IAC) Motor and Throttle Fig. 49 MAP Sensor Position Sensor (TPS) Wiring Connectors 1 – MAP SENSOR 1 – IAC 2 – PCM 3 –...
Page 1016 2001 PT CRUISER 2.0L DOHC ENGINE 9a - 33 REMOVAL AND INSTALLATION (Continued) (1) Perform fuel system pressure release procedure before attempting any repairs. Refer to FUEL SYSTEM for procedure. (2) Disconnect intake air temperature sensor. (3) Remove air filter housing and air inlet tube. (4) Disconnect negative cable from battery.
Page 1017 2001 PT CRUISER 9a - 34 2.0L DOHC ENGINE REMOVAL AND INSTALLATION (Continued) EXHAUST MANIFOLD (3) Install lower intake manifold. Tighten fasten- ers to 12 N·m (105 in. lbs.) in sequence shown in (Fig. 55). REMOVAL (1) Remove clean air hose and air cleaner housing. (2) Disconnect negative cable from battery.

Chrysler PT Cruiser 2001 Service Manual Supplement

8W-39 Vehicle Theft Security System

- Continued

Transmission

Verification Tests

Component Locations

Datalink

Pcm

Pressure Port

Throttle Position Sensor

Transmission Control Module

Transmission Control Relay

Transmission Component Location

Connector Pinouts

Schematic Diagrams

Quick Links

Chapters

Summary of Contents for Chrysler PT Cruiser 2001

Page 6: Vehicle Identification Number

Page 7: Body Code Plate

Page 8: Display Symbols

Page 10: Fastener Identification

Page 16: International Symbols

Page 17: Maintenance Schedules

Page 22: Jump Starting, Towing, And Hoisting

Page 646: Table Of Contents

Page 850: G300

Page 851: Left Lavalier Module

Page 852: Remote Keyless Entry Antenna

Chrysler PT Cruiser 2001 Service Manual Supplement

8W-39 Vehicle Theft Security System

- Continued

Transmission

Verification Tests

Component Locations

Datalink

Pcm

Pressure Port

Throttle Position Sensor

Transmission Control Module

Transmission Control Relay

Transmission Component Location

Connector Pinouts

Schematic Diagrams

Quick Links

Chapters

Related Manuals for Chrysler PT Cruiser 2001

Summary of Contents for Chrysler PT Cruiser 2001

Table of Contents