2015 pt cruiser dream cruiser owners manual
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2015 pt cruiser dream cruiser owners manualFollow the vehicle or Helicoil recommen- DESCRIPTION dations for application and repair procedures.DESCRIPTION The metric system is based on quantities of one, ten, one hundred, one thousand and one million.Refer to the Standard Torque Specifica- Fig. 7 TORQUE SPECIFICATIONS. Chrysler permanently attaches. Diamler- 1 - WHEEL BEARINGS Chrysler only recommends API Certified (GF-3) 2 - CHASSIS LUBRICATION 3 - CHASSIS AND WHEEL BEARINGS engine oils that meet the requirements of Material Standard MS-6395. It is even more important to look for gasoline with- Light spark knock at low engine speeds is not out MMT in Canada because MMT can be used at harmful to your engine. Inspect the brake linings. Replace the engine air cleaner filter. Inspect the brake linings. Change the brake fluid. Inspect the brake linings. Replace the engine air cleaner filter. Replace the spark plugs. Connect BLACK jumper cable clamp to engine ground as WARNING: DO NOT ALLOW TOWING ATTACHMENT close to the ground cable attaching point as possible. Press the hub out of the bearing race. Fig. 14 Wheel Bearing Installation 1 - PRESS RAM 2 - BEARING Fig. 13 Bearing Race Removal From Hub 1 - ARBOR PRESS (a) Place the studs in the three holes in the hub 2 - HUB. If the ball the steering knuckle and allows for the up and down joint is lubricated after installation to knuckle, dam- movement of the suspension during the jounce and. Install the cushion retainer The strut assembly cushions the ride of the vehicle, bolts, but do not completely tighten them at this controlling vibration, jounce and rebound of the sus- time. Follow the manufactur- er’s instructions closely. Inspect the axle looking for damage or bending. If damage is evident, the axle must be replaced. Inspect for broken or cracked welds at each end of the twist beam within the axle. Receiver, Special Tool 8405-1, installed, over the arm, 21). The stabilizer bar interconnects the rear axle with the frame rails of the vehicle (Fig. 35).http://www.athyartgroup.com/uploads/dynapar-max-count-2-user-manual.xml
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Attachment of the stabilizer bar to the rear frame rails of the vehicle is through 2 rubber-isolator stabi- lizer bar links. That is, it is used to control rear axle lateral movement and provides cross-car location of the axle. This is referred to as Net Build. The result is no required adjustment of camber and caster after the vehicle is built or when servicing the suspension components. CAUTION: Do not twist the inner tie rod-to-steering gear rubber boots while turning the inner tie rod during the front toe adjustment. Isolate the noise to one side of the vehicle. Support outer end of halfshaft assembly. If dif- ficulty separating halfshaft. If any parts show signs of exces- sive wear, the halfshaft assembly will require replacement. INDICATOR ON released. 2. Parking brake warning switch on 2. Check TRAVEL (ONE FRONT malfunctioning.An manner until all air is removed from the brake sys- empty reservoir will allow additional air into the tem. If pedal travel is ACTUATION: excessive or has not been improved, some air may Outlet Port Threads- still be trapped in the system.Push the switch into the fluid reservoir until switch. This seal provides a hydraulic seal between the piston and the cylinder wall (Fig. 6). Fig. 8 Adapter, Boots And Pins Fig. All vehicles Rear disc brakes are optional equipment on some equipped with rear disc brakes have a small duo- models of this vehicle (Fig. With the ically for evidence of corrosion, physical damage or lever in this position, back the star wheel adjustment contact with moving or hot components of the vehi- off approximately 10 notches. Also inspect for excessive lining deteriora- tion. Clean and inspect the brake support plate and shoe adjuster screw. If machining the drum will cause the drum to exceed maximum allowable diameter, do not machine the brake drum. It needs to be replaced. CAUTION: Do not machine the brake drum if it will cause the drum to exceed maximum allowable diameter.http://www.deco-interieure.com/userfiles/dynapar-max-length-1-manual.xml Use of such type fluids will result in seal damage of the vehicle DIAGNOSIS AND TESTING - BRAKE FLUID brake hydraulic system causing a failure of the CONTAMINATION vehicle brake system. Cylinder Bleed Tube, Special Tool 8358-2, to the (7) Remove the master cylinder from the vise.PEDAL - WITH AUTOMATIC (9) Connect the negative (ground) cable on the bat- TRANSAXLE tery. (10) Install the air cleaner housing. REMOVAL (11) Reinstall the air cleaner cover (two clips). (12) Fill the master cylinder to the proper level. Install a new retaining clip on the end of the pin (Fig. The vacuum loss should be less than 3.0 (8) Disconnect the vacuum hoses from the check inches Hg in 15 seconds time span. If the loss is valve on the power brake booster (Fig. 86), but do not more than 3.0 inches Hg, replace the power brake remove the check valve from power brake booster. Discard the original brake lamp switch. The switch can only be adjusted once. That switch. NOTE: Before proceeding, (Refer to 5 - BRAKES - INSTALLATION WARNING)(Refer to 5 - BRAKES - CAUTION). (1) Lubricate the O-ring on the proportioning (1) Using a brake pedal holder, depress the brake valve. To measure rotor runout on the vehicle, first remove the tire and wheel assembly. Install a new hub and bearing retaining wheel cylinder (Fig. 111). nut (Fig. The parking brakes consist of the following compo- (9) Remove old sealer from mounting surfaces. Install the two fasteners 127). AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL (18) Keeping your hands clear of the automatic INJURY. FAILURE TO OBSERVE CAUTION IN HANDLING THIS MECHANISM COULD LEAD TO SERIOUS INJURY. (1) Place the parking brake lever on the mounting studs on the vehicle floor. Position the screwdriver against the star wheel on the park- (1) Verify the parking brake lever is in the ing brake shoe adjuster. Although the ABS system prevents complete wheel After diagnosing the defective component, repair or lockup, some wheel slip is desired in order to achieve replace it as required. Do supplies more volume than the system requires.The If the brakes are applied at anytime during a trac- addition of aftermarket electrical equipment (car tion control cycle, the brake lamp switch triggers the. The connector is located under the lower steering column cover to the left of the steering DESCRIPTION SPECIFICATION column. The diagram shows no wheel spin or slip occurring relative to the speed of the vehicle. The HCU on a vehicle equipped with traction control has a valve DESCRIPTION block that is approximately one inch longer than a The hydraulic control unit (HCU) and the control-. This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved. LHD models have an adjustable pedal pushrod. Dur- ing a clutch pedal actuation, the hydraulic fluid DIAGNOSIS AND TESTING pressure applies additional force to the release lever. Replace clutch assembly. Driver frequently rides (slips) clutch, Replace clutch assembly.Insufficient clutch cover diaphragm Replace clutch assembly. Tighten drive plate bolts to specified torque COMPLAINTS only. Over-tightening can distort the drive plate hub For all clutch chatter complaints, perform the fol- causing excessive runout. If pedal still feels spongy, or clutch does not fully disengage, excessive air is still trapped within the system. Per- form the following procedure: (1) Verify fluid level in clutch master cylinder res- ervoir. Use care not to over-fill reservoir and spill fluid into engine compartment. (7) Operate bleed gun sufficiently to expel air upward through circuit and out of master cylinder reservoir. These vehicles only utilize the starter inhibit (interlock) feature. 1.6L and 2.2L Turbo Diesel models: With the clutch pedal at rest, the clutch pedal upstop switch is closed, allowing speed control operation. The engine starter should not crank with the clutch pedal at rest (not depressed). Proceed to to close the switch. These vehicles will only utilize the starter inhibit (interlock) feature. (1) Disconnect and isolate battery negative cable. Install and tighten brake booster contacting pedals.Be careful not to damage retention tabs on bearing. (4) Examine the condition of the bearing. It is pre-lubricated and sealed and should not be immersed in oil or solvent. The heavy weight of the flywheel relative to the rotating mass of the engine components serves to stabilize the flow of power to the remainder of the drivetrain. Aggressive han- cylinder assembly. (1) Install clutch master cylinder into position dling can result in a damaged hydraulic tube and improper clutch release operation upon reassembly. Verify connection by pulling outward on connection. (16) Lower vehicle. (17) Connect battery negative cable. (18) Install air cleaner assembly (Fig. 35). (19) Verify that reservoir is full. Top off with DOT 3 brake fluid if necessary. No fluid service or sys- tem bleeding should be required, unless the hydraulic system has lost an excessive amount of fluid and has ingested air into the master or slave cylinder assembly. Remove six (6) pressure plate-to-fly- wheel bolts (Fig. Allow brake fluid to drain into suitable container. Fig. 65 Clutch Slave Cylinder at Transaxle—1.6L Models 1 - SLAVE CYLINDER 2 - BOLT Fig. Replace the power steering belt’s automatic belt tensioner. 2. AUTOMATIC BELT TENSIONER AND PULLEY DESCRIPTION The automatic belt tensioner (Fig. 9) maintains proper tension on the power steering and air condi- tioning belt. Start draincock location.Hand tighten only. (10) Slowly fill the coolant recovery container to (2) Remove cooling system pressure cap. Install the FULL HOT mark with the recommended coolant. Special Tool 8195 Filling Aid Funnel (Fig. If a DESCRIPTION spring type clamp replacement is necessary, replace The coolant recovery system consists of a coolant with the original Mopar equipment spring type clamp. The heating element immersed in coolant (Fig. There is also a vent valve in the center of the cap. This valve also opens when coolant is cooling and contracting, allowing coolant to return to radiator from coolant recovery container by vacuum through. TO PREVENT SCALDING sensitive to small air leaks that will not cause cool- OR OTHER INJURY, THE PRESSURE CAP SHOULD ing system problems. The radiator and air conditioning fins should be cleaned when an accumulation of debris has occurred.DESCRIPTION (2) Disconnect positive battery cable. The water pump on this vehicle is attached to the (3) Remove battery.Diagnostic Procedures manual for SYSTEM SUSPECTED) operation of the DRB III scan tool. Diagnostic Procedure manual for OPEN). Once flow is detected install the pressure cap. Replace removed coolant into coolant recovery container.When additional coolant is needed, it should be NOTE: Do not remove pressure cap for routine added to the coolant recovery container (Fig. The higher pressure raises the coolant boiling point, allowing increased radiator cooling capacity.Use only a replacement cap that has a spring to hold the PLACE A SHOP TOWEL OVER THE CAP, AND WITH- OUT PUSHING DOWN, ROTATE IT COUNTER-. ENGINE COOLANT TEMPERATURE SENSOR DESCRIPTION The engine coolant temperature (ECT) sensor threads into the thermostat housing just below the. DIAGNOSIS AND TESTING - ENGINE COOLANT THERMOSTAT The thermostat is operated by a wax filled cham- ber (pellet) which is sealed. When heated coolant reaches a predetermined temperature the wax pellet expands enough to overcome the closing spring and water pump pressure, which forces the valve to open. REMOVAL NOTE: The fan motor, fan, and the shroud are ser- viced as an assembly.Care should be taken not to damage the cooling fins and tubes during removal. (10) Non-Turbo Vehicles: Remove the lower air seal from radiator (Fig. The radiator and air conditioning fins in. A defective pump will not provide an adequate flow of heated coolant through the sys- tem. To prevent potential leakage, the cooler hoses and clamps must be replaced. Replace fuse, if required. 2. Radio connector faulty. 2. Check for loose or corroded radio connector. Repair, if required. The radio then tunes and amplifies the weak radio signals into stronger electrical signals in order to operate the audio system speakers. DIAGNOSIS AND TESTING - ANTENNA BODY AND CABLE The following four tests are used to diagnose the. To begin this test, proceed as fol- lows: (1) This test must be performed with the battery positive cable disconnected from the battery. RADIO Connect the wire harness connectors at each end of the antenna.COMPONENTS (2) Remove instrument panel center bezel. (3) Remove mounting fasteners and remove radio DESCRIPTION from instrument panel (Fig. 6). Radio noise suppression devices are factory-in- stalled standard equipment on this vehicle. The use of braided ground straps in key locations is part of the RFI and EMI prevention strategy. These ground straps ensure adequate ground paths, particularly for high current components such as many of those found in the starting, charging, igni- tion, engine control and transmission control sys-. The chime will be a “fast” chime (same as DRIVERS DOOR IS OPEN door ajar). The transmission has reverse gear adja- (1) Remove the key from the ignition. These DTC’s will remain in the CAB mem- ory even after the ignition has been turned off. If a module is damaged or faulty, the entire sensor value input that is out of range or a shorted module must be replaced. WARNING: THERE ARE MANY SHARP METAL (3) Install the heated seat module on the power EDGES ON THE SEAT CUSHION FRAME AND SEAT seat cushion pan. Shift schedule selection is ately adjusts the shift schedule. If the PCM is replaced after 320 km (200 miles) of usage, update the mileage and vehicle iden- tification number (VIN) in the new PCM. Standard Procedure for the proper test ATTEMPTING TO START procedures. In addition to the maintenance schedules found in this service manual and the owner’s man- ual, it is recommended that these procedures be per- formed any time the battery or related components must be removed for vehicle service. Battery The following information details the recommended sizes and ratings are discussed in more detail below.The spiral plate battery is completely, per- manently sealed. Through gas recombination, hydro- DESCRIPTION.TORQUE gen and oxygen within the battery are captured Battery Hold Down Bolt. This reaction causes the battery to dis- IN THE EVENT OF CONTACT, FLUSH WITH WATER charge electrical current from its terminals. As the AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT battery discharges, a gradual chemical change takes OF THE REACH OF CHILDREN. Refer to Battery Diagnosis and appear that the battery will not accept charging cur- Testing for the proper battery test procedures. If the rent. See the instructions provided by the manufac- battery will endure a load test, return the battery to turer of the battery charger for details on how to service. TABLE Charging CAUTION: Always disconnect and isolate the bat- 5 Amps 8 Amps Amperage tery negative cable before charging a battery. Do not exceed sixteen volts while charging a battery. This voltage (2) Determine that the underhood lamp is operat- reading will indicate the battery state-of-charge, but ing properly, then disconnect the lamp wire harness will not reveal its cranking capacity. If a battery has connector or remove the lamp bulb. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault. If the replacement battery is not identical, in size to the original, it may be necessary to use non-corrosive spacers in between the hold down retainer to properly secure the battery in the battery tray. If excessive resistance is The battery cables are large gauge, stranded cop- found in the battery cable connections, the connec- per wires sheathed within a heavy plastic or syn-. If the reading is still above 0.2 volt, replace the faulty battery positive cable. Fig. 17 Testing Battery Negative Connection Resistance Fig. 19 Testing Battery Positive Cable Resistance 1 - VOLTMETER 2 - BATTERY 1 - BATTERY 2 - VOLTMETER. Refer to OPERATION the procedure in this group. The battery tray provides a secure mounting loca- (4) One at a time, trace the battery cable retaining tion and supports the battery. The tem- perature of the battery can affect battery perfor- On gasoline engine equipped vehicles, a flexible mance. The air trapped in the thermal guard creates thermal guard wraps around the battery case to a dead air space, which helps to insulate the sides of enclose the sides of the battery (Fig. REMOVAL (2) Raise the vehicle on the hoist. (1) Disconnect and isolate the negative battery (3) Working under the vehicle, install the two bat- cable. If an extreme condition is indicated, the lamp will be illuminated. This is INSPECTION done as reminder to check the three gauges. The sig- The Powertrain Control Module (PCM) monitors nal to activate the lamp is sent via the PCI bus cir- critical input and output circuits of the charging sys- cuits. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. It is serviced only as a complete assembly. If the genera- tor fails for any reason, the entire assembly must be replaced. REMOVAL - 2.4L TURBO (10) Unplug field circuit from generator (Fig. 11). The generator is located above the oil filter and axle shaft (Fig. 13). Fig. 11 Battery Connection 1 - FIELD CONNECTOR Fig. NOTE: The orientation of the generator (Fig. 25), it (16) Install the air cleaner lid and connect the will fit onto the bracket backwards. The amount of DC current produced by the gener- (18) Lower vehicle.Charge or replace the battery, if required. Refer to the Battery section solenoid for indications of physical damage and loose for more information.Refer to the PDC label for relay identification and location. Refer to the Ignition Section times. If voltage reads above 0.2 volt, (4) Verify that all lights and accessories are OFF, correct poor starter to engine ground.INSTALLATION - 1.6L (1) Install the starter through the wheel well (Fig. (2) Install the lower mounting bolt. (3) Install the upper mounting bolts. Refer to the appropriate wiring information. ILLUMINATION WITH Replace fuse, if required.Refer to the Body section of this manual for the pro- cedure. Refer to the Body section of the ser- The heated seat elements resist the flow of electri- vice manual for the procedures.The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs by five integral male spade-type terminals that extend from the bottom of the relay base. If OK, nal cavities in the receptacle. Move the lead toward the break and voltage will change as soon as the break is crossed.When energized, the ASD relay on NGC vehicles provides power to operate the injectors, ignition coil, generator field, O2 sensor heaters (both upstream and downstream), evaporative purge solenoid, EGR. If magnet cracks replace it. (1) Disconnect the negative battery cable. (2) Install camshaft position sensor. Tighten sensor (2) Relocate the power steering return hose.The coil fires two spark plugs every power tle body. The coil pack towers are numbered with the cylinder (1) Install coil capacitor and mounting bolt and identification. Long term memory stores previous detonation information in its battery-backed RAM. The maxi- mum authority that long term memory has over tim- ing retard can be calibrated. REMOVAL - 1.6L NOTE: REMOVE cables from coil first before remov- ing spark plug insulator. Over tightening can cause distortion resulting in a change in the spark plug gap. Overtightening can also damage the cylinder head. (1) To avoid cross threading, start the spark plug into the cylinder head by hand. When selecting tires, pay attention to the original size as marked on the tire.The stiffer, heavier snow tires will noticeably change the turning and braking characteristics of the vehicle.Use a quality air pressure gauge Click to enlarge Common tire wear patterns and causes Click to enlarge A plate or sticker is normally provided somewhere in the vehicle (door post, hood, tailgate or trunk lid) which shows the proper pressure for the tires. In fact, many states have laws prohibiting the use of tires with less than this amount of tread. Tread wear indicators will appear when the tire is worn Accurate tread depth indicators are inexpensive and handy You can check your own tread depth with an inexpensive gauge or by using a Lincoln head penny. The use of premium grades may actually cause driveability problems. Also, Ford recommends that using gasoline with an octane rating lower than 87 can cause persistant and heavy knocking, and may cause internal engine damage. Be sure to insert it all the way. Pull out the dipstick and note the oil level. It should be between the FULL(MAX) mark and the ADD(MIN) mark. Use a rag to shield your fingers from the heat. Push in on the plug as you unscrew it so you can feel when all of the screw threads are out of the hole (and so you will keep the oil from seeping past the threads until you are ready to remove the plug). Check the drain plug to make sure the threads and sealing surface are not damaged. When you install the new filter, smear a small amount of fresh oil on the gasket with your finger, just enough to coat the entire contact surface. Top off the oil at this time to the fill mark. If the vehicle is not resting on level ground, the oil level reading on the dipstick may be slightly off. Be sure to check the level only when the car is sitting level. Remember that the fluid will likely flow with some force at first (arcing outward from the transmission), and will not just drip straight downward into the pan. Position the drain pan accordingly and move it more directly beneath the drain plug as the flow slows to a trickle. Wipe away any dirt in the area of the dipstick to prevent it from falling into the filler tube.Loosen all of the pan attaching bolts to within a few turns of complete removal Loosen all of the pan attaching bolts to within a few turns of complete removal, then carefully break the gasket seal allowing most of the fluid to drain over the edge of the pan. DO NOT use a cloth to dry the pan which might leave behind bits of lint. Discard the old pan gasket.Make sure any gaskets or seals are removed with the old filter. LEVEL CHECK Position the vehicle on level ground.The fluid level should be up to the fill hole.On models with the front locking differential, add 2 oz.Like the manual transmission which is available, the rear axle does not have a dipstick to check fluid level. Instead, a filler plug is located in the side of the housing (or in the side of the cover), at a level just barely above the level to which fluid should fill the housing. Check under the vehicle to see if there is sufficient clearance for you to access the filler plug on the side of the differential housing. This will help prevent dirt from contaminating the differential housing while the cover is removed. A putty knife is a good tool to use for this. You may want to cover the differential gears using a rag or piece of plastic to prevent contaminating them with dirt or pieces of the old gasket. Choose an aluminum compatible, good quality antifreeze with water pump lubricants, rust inhibitors and other corrosion inhibitors along with acid neutralizers. Use a funnel to avoid spills At least annually or every 12,000 miles (19,000 km), all hoses, fittings and cooling system connections should be inspected for damage, wear or leaks. At least once every 3 years or 36,000 miles (48,000 km), the engine cooling system should be inspected, flushed and refilled with fresh coolant. If the coolant is left in the system too long, it loses its ability to prevent rust and corrosion. Don't wiggle the fins back and forth too much. Straighten them once and try not to move them again.Open the radiator and engine drains (petcocks) or disconnect the bottom radiator hose at the radiator outlet. If equipped with a coolant recovery system, flush the reservoir with water and leave empty. To refill the system with coolant, remove the radiator cap.Once the temperature has been reached, shut the engine OFF, and check for leaks around the hose fittings and connections which were removed earlier. For the removal procedures see the appropriate Section for you vehicle. For 4 wheel drive vehicles, see Section 7. For 2 wheel drive vehicles, see Section 8. Sodium based grease is not compatible with lithium based grease. Be careful not to mix the two types. The best way to prevent this is to completely clean all of the old grease from the hub assembly before installing any new grease. Add grease to the hub until the grease is flush with the inside diameter of the bearing cup.Be careful not to damage the grease seal. Place the outer bearing into position on the spindle and into the bearing cup. Install the adjusting nut finger tight. It is important to remember that towing a trailer will place additional loads on your vehicles engine, drivetrain, steering, braking and other systems. However, if you decide to tow a trailer, using the prior equipment is a must. Local laws may require specific equipment such as trailer brakes or fender mounted mirrors. If a flat bed tow truck is not available, tow the vehicle with the rear wheels lifted, front hubs unlocked (4WD models) and the steering wheel locked in the straight ahead position using a clamping device designed for towing. Severe damage to the transmission can occur if these limits are exceeded. If your truck has to be towed backward and is a 4WD model, unlock the front axle driving hubs, to prevent the front differential from rotating and place the transfer case in Neutral. Sparks should always be avoided when working around batteries, especially when attaching jumper cables. Jump Starting Procedure. This is because if the drive train is engaged, power is transmitted to the wheel with the best traction and the vehicle will drive off the jack, resulting in possible damage or injury. Be sure and block the diagonally opposite wheel to prevent the vehicle from moving. When raising the vehicle on a hoist, position the front end adapters under the center of the lower suspension arm or the spring supports as near to the wheels as practical. The leading edge of the SPOUT signal is used by the ICM in the same manner as during the push start mode. The falling edge of the signal is generated to control the timing for turning the ignition coil on (the ICM no longer controls this function as during the push start mode). Place the gear shift lever in Neutral (manual transmission) or Park (automatic transmission). Disconnect the Sterminal wire at the starter relay. Attach a remote starter switch. Turn the ignition switch to theRUNposition. Crank the engine Turn the ignition switch OFF. If a spark did occur, check the PIP and ignition ground wires for continuity. If okay, the problem is not in the ignition system. This procedure checks the capability of the ignition module to receive the spark timing command from the EEC module. Turn the ignition switch OFF. Turn the ignition switch OFF. If a spark did occur, measure the resistance of the ignition coil wire, replace it if the resistance is greater than 7000 ohms per foot. Check for dirt, corrosion or damage.If necessary, at this time the radio ignition interference capacitor can be removed from the ignition coil. Label and detach all wiring from the ICM.