2002 Chrysler PT Cruiser Factory Service & Repair Manual (P/N 81-370-02061, 81-170-02002)

The factory service manual for the 2002 Chrysler PT Cruiser hatchback covers LHD/RHD vehicles, with U.S., Canadian, Mexican, and international identification data.

A 1,755-page PDF, supplied in one ZIP archive. Some engine pages contain overlapping text and illustrations; affected pages are identified in the file notes below.

• Gasoline engine repair: Removal and installation, compression and combustion-leakage testing, cylinder-head and valvetrain service, lubrication diagnosis, and timing-system repair.

• Transaxle and driveline work: NV T350 and 41TE teardown, cleaning, inspection, reassembly, and installation; automatic-transaxle road, hydraulic-pressure, and clutch-air tests; half-shaft and inner/outer CV-boot service.

• Suspension, steering, and brakes: MacPherson struts, twist-beam rear axle, Watts linkage, curb-height and four-wheel alignment, power steering, and Mark 20e ABS/traction control with DRB III-assisted bleeding.

• Electrical diagnosis: Circuit testing, wire/terminal repair, power and ground distribution, PCI-bus systems, powertrain and transmission control modules, Sentry Key security, charging/starting, lighting, restraints, and power accessories.

• Fuel, cooling, and emissions: Fuel-injection component service, cooling-system leak and flow tests, water-pump work, EVAP/ORVR diagnosis, and EGR component replacement.

• Body and climate systems: Water-leak and wind-noise diagnosis, plastic-panel repair, doors, liftgate, glass, sunroof, seats, body opening and weld-location data, plus heater/A/C performance and leak testing, refrigerant recovery, evacuation, and charging.

• Factory reference data: Assembly-specific torque tables, fluid and lubricant requirements, clearances, wear limits, pressure and electrical test values, adjustment data, and illustrated special-tool identification.

The material is suited to professional technicians and experienced repairers who can interpret factory specifications and use a DRB III scan tool, presses, spring compressors, refrigerant service equipment, and approved lifting gear.

Gasoline Engine Repair and Timing

VIN and body-code tables identify EJD 1.6L SOHC, ECC 2.0L DOHC, and EDZ 2.4L DOHC gasoline engines. Their repair chapters cover camshaft and crankshaft inspection, piston and bearing fitting, oil-pump work, oil-pressure checks, engine mounting, and cylinder-head removal, valve work, and seat service.

Timing-system removal, installation, and verification cover the 1.6L timing chain and the 2.0L/2.4L timing belts. Timing work is configuration-specific: the 1.6L and 2.0L are non-free-wheeling designs, while the 2.4L can suffer valve-to-valve contact if its camshafts are rotated independently.

NV T350 and 41TE Transaxle Repair

Identification tables distinguish DD5 NV T350, DGL 41TE, and DDD Getrag 288 transaxles. Internal repair procedures cover the T350 and 41TE.

The T350 chapter handles shafts, gears, synchronizers, the differential, seals, and shift-cable repair. The fluid specification changes between domestic and export production; using or mixing the wrong lubricant can cause hard shifting and bearing, gear, or synchronizer failure.

The 41TE section covers valve-body, clutch-pack, pump, torque-converter, and final-drive repair, including input and holding clutch assemblies, the planetary geartrain, and differential-bearing preload. TCM Pinion Factor and Quick Learn procedures are also documented.

Road-test information, hydraulic schematics, and clutch-air tests help distinguish a slipping clutch or hydraulic fault before choosing the repair work.

Suspension and Brake Service

Chassis procedures cover strut disassembly, front wheel-bearing pressing, steering-knuckle replacement, lower control arms and ball joints, rear-axle removal and pivot-bushing replacement, hub/spindle service, and front/rear camber and toe adjustment. Base-brake coverage includes hydraulic bleeding, caliper overhaul, drum-brake adjustment, parking-brake service, wheel-speed sensors, and the integrated ABS hydraulic/control unit.

The safety information addresses altered vehicle balance when the engine or rear suspension is removed, stored spring energy, brake and refrigerant hazards, and airbag-system isolation.

Fuel Delivery, Cooling, and Emissions

Cooling coverage distinguishes the 1.6L water-pump/power-steering-pump assembly from the 2.0L/2.4L arrangement. Fuel and emissions sections address injectors, throttle bodies, the leak detection pump, and diagnosis of a tank that will not fill through the ORVR system.

Factory Diagrams and Special Tools

Electrical references include Fuel/Ignition System, Transmission Control System, Antilock Brakes, and Occupant Restraint System diagrams, plus Connector/Ground/Splice Location views and connector pin-outs. The 41TE Transaxle Hydraulic Schematics support automatic-transmission diagnosis.

Illustrated tool pages identify rear-suspension Remover/Installer 8405, Ball Joint Press C-4212F, Clutch Line Disconnect 6638A, Clutch Disc Alignment Tool 6724, and 41TE High Pressure Gauge C-3293SP. Specifications accompany the relevant repair chapters.

Diesel Coverage and Diagnostic Limits

The EDJ 2.2L turbo diesel receives identification data and selected battery, instrument, and cabin-heater coverage. There is no full diesel engine mechanical chapter or Getrag 288 teardown chapter.

DTC lists are included, but complete fault-isolation procedures refer to separate Powertrain, Transmission, Chassis, or Body Diagnostic Procedures information. Owner operating instructions, detailed maintenance schedules, and New Vehicle Preparation are outside this manual.

File Format and Readability

The page total includes the Group Tab Locator (1 page), Component and System Index (32 pages), Service Manual Comments form and return-address page (2 pages), and 32 blank divider pages. These are already included in the total; no separate supplement is supplied.

Text search and navigation: Service text and many reference tables are searchable; 214 wiring-section pages have no searchable text. There are no embedded PDF bookmarks.

Readability: Small wiring labels require zooming. PDF pages 979, 993, 1057, and 1072 contain overlapping engine text or illustrations that obscure parts of the gasket-surface and cylinder-head information.