service CHRYSLER PT CRUISER 2005 1.G Service Manual

Air Conditioner Maintenance
For best possible performance, your air conditioner
should be checked and serviced by an Authorized Dealer
at the start of each warm season. This service should
include cleaning of the condenser fins and a performance
test. Drive belt tension should also be checked at this
time.WARNING!
•Use only refrigerants and compressor lubricants
approved by the manufacturer for your air condi-
tioning system. Some unapproved refrigerants are
flammable and can explode, injuring you. Other
unapproved refrigerants or lubricants can cause
the system to fail, requiring costly repairs. Refer
to Section 3 of the Warranty Information book for
further warranty information.
•The air conditioning system contains refrigerant
under high pressure. To avoid risk of personal
injury or damage to the system, adding refrigerant
or any repair requiring lines to be disconnected
should be done by an experienced repairman.
MAINTAINING YOUR VEHICLE 279
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Refrigerant Recovery and Recycling
R-134a Air Conditioning Refrigerant is a hydrofluorocar-
bon (HFC) that is endorsed by the Environmental Pro-
tection Agency and is an ozone-saving product. How-
ever, the manufacturer recommends that air conditioning
service be performed by dealers or other service facilities
using recovery and recycling equipment.
NOTE:Use only manufacturer approved A/C System
Sealers, Stop Leak Products, Seal Conditioners, Compres-
sor Oil, or Refrigerants.
Power Steering — Fluid Check
Checking the power steering fluid level at a defined
service interval is not required. The fluid should only be
checked if a leak is suspected, abnormal noises are
apparent, and/or the system is not functioning as antici-
pated. Coordinate inspection efforts through a certified
DaimlerChrysler Dealership.
WARNING!
Fluid level should be checked on a level surface and
with the engine off to prevent injury from moving
parts and to insure accurate fluid level reading. Do
not overfill. Use only manufacturers recommended
power steering fluid.
If necessary, add fluid to restore to the proper indicated
level. With a clean cloth, wipe any spilled fluid from all
surfaces. Refer to Recommended Fluids, Lubricants, and
Genuine Parts for correct fluid types.
Front Suspension Ball Joints
There are two front suspension lower ball joints that are
permanently lubricated. Inspect these ball joints when-
ever under vehicle service is done. Damaged seals and
their corresponding potentially damaged ball joints must
be replaced.
280 MAINTAINING YOUR VEHICLE

Body Lubrication
Locks and all body pivot points, including such items as
seat tracks, doors,liftgate and hood hinges, should be
lubricated periodically to assure quiet, easy operation
and to protect against rust and wear. Prior to the appli-
cation of any lubricant, the parts concerned should be
wiped clean to remove dust and grit; after lubricating
excess oil and grease should be removed. Particular
attention should also be given to hood latching compo-
nents to insure proper function. When performing other
underhood services, the hood latch, release mechanism
and safety catch should be cleaned and lubricated.
The external lock cylinders should be lubricated twice a
year, preferably in the fall and spring. Apply a small
amount of a high quality lubricant such as MoparLock
Cylinder Lubricant directly into the lock cylinder.
Windshield Wiper Blades
Clean the rubber edges of the wiper blades and the
windshield periodically with a sponge or soft cloth and a
mild non abrasive cleaner or use the washer solvent. This
will remove accumulations of salt, waxes or road film
and help reduce streaking and smearing.
Operation of the wipers on dry glass for long periods
may cause deterioration of the wiper blades. Always use
washer fluid when using the wipers to remove salt or dirt
from a dry windshield. Avoid using the wiper blades to
remove frost or ice from the windshield. make sure that
they are not frozen to the glass before turning them on to
avoid damaging the blade. Keep the blade rubber out of
contact with petroleum products such as engine oil,
gasoline, etc.
Windshield Wiper Blade Replacement
1. Lift the wiper arm away from the glass.
MAINTAINING YOUR VEHICLE 281
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WARNING!
•The warning words “DO NOT OPEN HOT” on
the cooling system pressure cap are a safety pre-
caution. Never add coolant when the engine is
overheated. Do not loosen or remove the cap to
cool an overheated engine. Heat causes pressure
to build up in the cooling system. To prevent
scalding or injury, do not remove the pressure cap
while the system is hot or under pressure.
•Do not use a pressure cap other than the one
specified for your vehicle. Personal injury or
engine damage may result.
Disposal of Used Engine Coolant
Used ethylene glycol based engine coolant is a regulated
substance requiring proper disposal. Check with your
local authorities to determine the disposal rules for your
community. To prevent ingestion by animals or childrendo not store ethylene glycol based engine coolant in open
containers or allow it to remain in puddles on the
ground. If ingested by a child, contact a physician
immediately. Clean up any ground spills immediately.
Coolant Level
The coolant bottle provides a quick visual method for
determining that the coolant level is adequate. With the
engine idling, and warm to normal operating tempera-
ture, the level of the coolant in the bottle should be
between the ranges indicated on the bottle.
The radiator normally remains completely full, so there is
no need to remove the radiator cap unless checking for
coolant freeze point or replacing coolant. Advise your
service attendant of this. As long as the engine operating
temperature is satisfactory, the coolant bottle need only
be checked once a month.
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Brake System
In order to assure brake system performance, all brake
system components should be inspected periodically.
Suggested service intervals can be found in the Mainte-
nance Section.
WARNING!
Riding the brakes can lead to brake failure and
possibly an accident. Driving with your foot resting
or riding on the brake pedal can result in abnormally
high brake temperatures, excessive lining wear, and
possible brake damage. You wouldn’t have your full
braking capacity in an emergency.
Brake And Power Steering System Hoses
When servicing the vehicle for scheduled maintenance,
inspect the surface of the hoses and nylon tubing for
evidence of heat and mechanical damage. Hard and
brittle rubber, cracking, tears, cuts, abrasions, and exces-
sive swelling suggest deterioration of the rubber. Particu-
lar attention should be made to examining those hose
surfaces nearest to high heat sources, such as the exhaust
manifold.
Inspect all hose clamps and couplings to make sure they
are secure and no leaks are present.
Insure nylon tubing in these areas has not melted or
collapsed.
290 MAINTAINING YOUR VEHICLE

NOTE:Often, fluids such as oil, power steering fluid,
and brake fluid are used during assembly plant opera-
tions to ease the assembly of hoses to couplings. There-
fore, oil wetness at the hose-coupling area is not neces-
sarily an indication of leakage. Actual dripping of hot
fluid when systems are under pressure (during vehicle
operation) should be noted before a hose is replaced
based on leakage.
NOTE:Inspection of brake hoses should be done when-
ever the brake system is serviced and at every engine oil
change.WARNING!
Worn brake hoses can burst and cause brake failure.
You could have an accident. If you see any signs of
cracking, scuffing, or worn spots, have the brake
hoses replaced immediately.
Brake Master Cylinder
The fluid level in the master cylinder should be checked
when performing under hood services, or immediately if
the brake system warning lamp is on.
Be sure to clean the top of the master cylinder area before
removing the cap. If necessary, add fluid to bring the
fluid level up to the requirements described on the brake
fluid reservoir. Fluid level can be expected to fall as the
brake pads wear. Brake fluid level should be checked
when pads are replaced. However, low fluid level may be
caused by a leak and a checkup may be needed.
MAINTAINING YOUR VEHICLE 291
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NOTE:If your vehicle is equipped with a manual
transaxle, the Brake Fluid Reservoir supplies fluid to both
the Brake System and the Clutch Release System. The
two systems are separated in the reservoir and a leak in
one system will not affect the other system. If the Brake
Fluid Reservoir is low, and the brake system does not
indicate any leaks or other problems, it may be a result of
a leak in the Hydraulic Clutch Release System. See your
local authorized dealer for service.
Use only manufacturers recommended brake fluid, refer
to Recommended Fluids, Lubricants and Genuine Parts
for correct fluid type.
Brake Fluid Master Cylinder
292 MAINTAINING YOUR VEHICLE

CAUTION!
Using a transmission fluid other than the manufac-
turers recommended fluid may cause deterioration
in transmission shift quality and/or torque converter
shudder. Using a transmission fluid other than the
manufacturers recommended fluid will result in
more frequent fluid and filter changes. Refer to
Recommended Fluids, Lubricants and Genuine Parts
for correct fluid type.
Fluid Level Check
The fluid level in the automatic transaxle should be
checked whenever the vehicle is serviced. Operation with
an improper fluid level will greatly reduce the life of the
transaxle and of the fluid.
Procedure For Checking Fluid Level
To properly check the automatic transaxle fluid level, the
following procedure must be used:
1. The vehicle must be on level ground.
2. The engine should be running at curb idle speed for at
minimum of 60 seconds.
3. Fully apply parking brake.
4. Place the gear selector momentarily in each gear
position ending with the lever in P (PARK).
5. Remove the dipstick and determine if the fluid is hot
or warm. Hot fluid is approximately 180°F (82°C), which
is the normal operating temperature after the vehicle has
been driven at least 24 km (15 miles). The fluid cannot be
comfortable held between the finger tips. Warm is when
the fluid is between 85° to 125°F (29° to 52°C).
294 MAINTAINING YOUR VEHICLE

EMISSION CONTROL SYSTEM MAINTENANCE
The “Scheduled” maintenance services, listed inbold
typemust be done at the times or mileages specified to
assure the continued proper functioning of the emission
control system. These, and all other maintenance services
included in this manual, should be done to provide best
vehicle performance and reliability. More frequent main-
tenance may be needed for vehicles in severe operating
conditions such as dusty areas and very short trip
driving.
Inspection and service also should be done any time a
malfunction is suspected.
NOTE:Maintenance, replacement, or repair of the emis-
sion control devices and systems on your vehicle may be
performed by any automotive repair establishment or
individual using any automotive part which has been
certified pursuant to U.S. EPA or, in the State of Califor-
nia, California Air Resources Board regulations.
MAINTENANCE SCHEDULE
There are three maintenance schedules that showre-
quiredservice for your vehicle.
First is Schedule“B”—ALL ENGINES. It is for vehicles
that are operated under the conditions that are listed
below and at the beginning of the schedule.
•Day and night temperatures are below 32° F (0° C).
•Stop and go driving.
•Extensive engine idling.
•Driving in dusty conditions.
•Short trips of less than 10 miles (16 km).
•More than 50% of your driving is at sustained high
speeds during hot weather, above 90° F (32° C).
•Trailer towing.†
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•Taxi, police, or delivery service (commercial ser-
vice).†
•Off-road or desert operation.
•If equipped for and operating with E-85 (ethanol)
fuel.
NOTE:IfANYof these apply to you then change your
engine oil every 3,000 miles (5 000 km) or 3 months,
whichever comes first, and follow schedule “B—All
Engines” of theMaintenance Schedulessection of this
manual.
NOTE:IFANYof these apply to you then flush and
replace the engine coolant every 102,000 miles (164,000
km) or 60 months, whichever comes first, and follow
schedule “B—All Engines” of theMaintenance Sched-
ulessection of this manual.
NOTE:Most vehicles are operated under the conditions
listed for ScheduleB—ALL ENGINES.Second is Schedule“A”—NON TURBO. It is for vehicles
that are not operated under any of the conditions listed
under ScheduleB—ALL ENGINES.
Third is Schedule“A”—TURBO. It is for vehicles that are
not operated under any of the conditions listed under
ScheduleB—ALL ENGINES.
Use the schedule that best describes your driving condi-
tions. Where time and mileage are listed, follow the
interval that occurs first.
CAUTION!
Failure to perform the required maintenance items
may result in damage to the vehicle.
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