Segment:
Compact MPV/Hatchback
Unique Selling Proposition:
Retro-futuristic styling, versatile interior, distinctive niche appeal
Primary Competitors 2004:
Ford Focus Wagon, Honda Civic Hatchback, Mazda3 Hatchback, Volkswagen Golf
Design:
Distinctive '30s hot rod inspired styling, tall profile, large glass area.
Interior Versatility:
High seating position, flexible seating arrangements (Fold-and-Tumble rear seats), generous headroom.
Completeness:
Provides factory-level repair information, essential for maintaining all aspects of the PT Cruiser, including the specialized diesel variant.
Diagnostic Focus:
Detailed diagnostic trees and troubleshooting guides enable efficient problem-solving.
Primary Coverage:
Full Service and Repair for 2004 Chrysler PT Cruiser
Supplemental Coverage:
Diesel Engine Service and Repair (2.2L CRD Turbo Diesel)
Main Manual Estimated Pages:
2000+
Diesel Supplement Estimated Pages:
300+
Type:
Factory Authorized Service & Repair Manual
Diesel Type:
Supplemental Diesel Service Manual
Format:
Digital (PDF) - Searchable and Printable
Powertrain:
Engine Mechanical (2.4L NA/Turbo & 2.2L CRD), Fuel System, Ignition System, Exhaust System, Cooling System, Lubrication System, Diesel Fuel Injection System (CRD), Turbocharger System (Turbo/CRD)
Transmission:
Automatic Transmission (41TE/42LE), Manual Transmission (MB5), Clutch System, Drivetrain Components (Axles, Driveshafts)
Chassis:
Suspension (Front/Rear), Steering System, Braking System (Front/Rear Disc), ABS System
Electrical:
Battery, Charging System, Starting System, Lighting System, Instrument Cluster, Body Control Module (BCM), Powertrain Control Module (PCM), Comfort & Convenience Systems, Audio Systems, Power Accessories (Windows, Locks, Mirrors)
Body & Interior:
Body Panels, Doors, Hood, Trunk, Glass, Interior Trim, Seats, HVAC System (Manual & Automatic Climate Control)
Maintenance:
Scheduled Maintenance Intervals, Oil Changes, Filter Replacements, Fluid Checks and Replacements, Belt Inspections and Replacements, Spark Plug Replacement, Diesel Glow Plug Service
Diagnostics:
Troubleshooting Charts, Diagnostic Trouble Codes (DTCs) Interpretation and Resolution, Wiring Diagrams, Component Testing Procedures
Repairs:
Engine Component Rebuilds (Pistons, Rings, Valves), Cylinder Head Repair, Turbocharger Replacement, Diesel Injector Service, Transmission Overhaul, Brake Component Replacement, Suspension and Steering Component Replacement, Electrical Component Diagnosis and Replacement, Body Panel Repair and Replacement
Specifications:
Torque Specifications, Clearances, Tolerances, Diagnostic Data
Depth:
Comprehensive, from basic fluid services to complete engine and transmission overhauls, including detailed diagnostic procedures and wiring schematics. Suitable for professional technicians and advanced DIY enthusiasts.
Displacement Hp:
2.4L (141 cu in) DOHC Inline-4 producing 150 hp @ 5900 rpm (Naturally Aspirated)
Displacement Torque:
2.4L (141 cu in) DOHC Inline-4 producing 160 lb-ft @ 4000 rpm (Naturally Aspirated)
Displacement Hp:
2.4L (141 cu in) DOHC Turbocharged Inline-4 producing 180 hp @ 5200 rpm (GT Model)
Displacement Torque:
2.4L (141 cu in) DOHC Turbocharged Inline-4 producing 205 lb-ft @ 3600 rpm (GT Model)
Displacement Hp:
2.2L (135 cu in) CRD Turbocharged Inline-4 Diesel producing 115 hp @ 4000 rpm
Displacement Torque:
2.2L (135 cu in) CRD Turbocharged Inline-4 Diesel producing 221 lb-ft @ 1750 rpm
System:
Sequential Multi-Port Fuel Injection (MPI)
System:
Common Rail Direct Injection (CRDi) with Turbocharging
Controls:
Catalytic Converter, Oxygen Sensors, EGR (Diesel)
NHTSA Front Crash Test:
★★★★☆ (4 stars)
NHTSA Side Impact Front Seat:
★★★★☆ (4 stars)
IIHS Moderate Overlap Frontal Offset:
Good
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Available Traction Control System (TCS) on some models
Airbags:
Standard Frontal Airbags, Optional Side Curtain Airbags
Seatbelts:
Pretensioner seatbelts with load limiters
Audio System Standard:
AM/FM CD player with 6 speakers
Audio System Optional:
Premium Infinity sound system, AM/FM Cassette/CD player, steering wheel mounted audio controls
Navigation Availability:
Not available on 2004 models
Parking Sensors:
Not available
Auxiliary Input:
Not standard, may be aftermarket addition
Service Intervals Oil Gas
Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first, using synthetic or synthetic blend oil.
Service Intervals Oil Diesel
Interval:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first, using diesel-specific engine oil.
Service Intervals Air Filter Gas
Interval:
Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).
Service Intervals Air Filter Diesel
Interval:
Inspect every 10,000 miles (16,000 km), replace as needed or every 20,000 miles (32,000 km).
Service Intervals Spark Plugs Gas
Interval:
Replace every 60,000 miles (96,000 km) with platinum-tipped plugs.
Service Intervals Coolant
Interval:
Flush and replace every 30,000 miles (48,000 km) or 2 years.
Service Intervals Timing Belt Gas
Interval:
Replace every 100,000 miles (160,000 km) or 7 years (non-interference engine).
Fluid Specifications Engine Oil
Gas 2.4L:
SAE 5W-30 (Synthetic Recommended)
Diesel 2.2L Crd:
SAE 5W-40 API CJ-4 or equivalent (Diesel Specific)
Fluid Capacities Engine Oil
2.4L (With Filter):
4.5 US quarts (4.3 L)
2.2L Crd (With Filter):
5.5 US quarts (5.2 L)
Engine:
Oil leaks from valve cover gasket, piston slap on early 2.4L engines, occasional turbocharger issues on GT models, diesel glow plug system concerns.
Transmission:
Occasional issues with solenoids or valve body in automatic transmissions, clutch wear on manual transmissions.
Electrical:
Window regulator failures, power lock actuator issues, intermittent issues with door modules and body control modules.
Suspension:
Front end noise, worn ball joints, tie rod ends, and strut mounts.
Diesel Specific:
Potential for injector seal leaks, EGR valve issues, and fuel pump component failures if not maintained with proper diesel fuel and filters.
Marque:
Chrysler, an American automobile manufacturer with a long history of innovation and luxury, later part of Fiat Chrysler Automobiles (FCA) and now Stellantis.
First Generation:
2001-2010
Facelift:
Minor styling updates throughout its lifecycle, with a more significant update around 2007.
Manufacturing Location:
Toluca, Mexico
Key Milestones 2004:
Continued sales success, availability of the potent turbocharged engine and the efficient diesel variant in select markets.
