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2005 Chrysler PT Cruiser CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chrysler REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Cabin Air Filter Locations & Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
BRAKE SERVICE PROCEDURES FOR 2005 Chrysler PT Cruiser AUTOMOBILES
Drum Brakes -> DaimlerChrysler -> Precautions
Vehicle: 2005 Chrysler PT Cruiser 2.4 L4 GAS
When working on or around brake assemblies, care must be taken to prevent breathing asbestos dust, as many manufacturers incorporate asbestos fibers in the production of brake linings. During routine service operations, the amount of asbestos dust from brake lining wear is at a low level due to a chemical breakdown during use, and a few precautions will minimize exposure. Do not sand or grind brake linings unless suitable local exhaust ventilation equipment is used to prevent excessive asbestos ex...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2005 Chrysler PT Cruiser AUTOMOBILES
DaimlerChrysler Corp./Jeep Light Trucks, SUVs & Vans -> Fuel Filter Replacement -> PT Cruiser
Vehicle: 2005 Chrysler PT Cruiser 2.4 L4 GAS
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental spray of ...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2005 Chrysler PT Cruiser AUTOMOBILES
CV AXLE SHAFT, Replace -> Install -> Remove
Vehicle: 2005 Chrysler PT Cruiser 2.4 L4 GAS
Remove
- Disconnect negative battery cable.
- Place transaxle in gated park.
- Raise vehicle on hoist.
- Remove wheel and tire assembly.
- Remove cotter pin, nut lock, spring washer and hub nut from end of outer C/V joint stub axle.
- On models equipped with ABS, disconnect front wheel speed sensor and secure harness out of the way.
- Remove nut and bolt retaining ball joint stud into steering knuckle.
- Separate ball joint stud from steering knuckle by prying down on lower control arm. Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get damaged.
- Rem...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2005 Chrysler PT Cruiser AUTOMOBILES
Alternator, Replace
Vehicle: 2005 Chrysler PT Cruiser 2.4 L4 GAS
- Remove air cleaner lid, disconnect inlet air sensor and makeup air hose.
- Remove battery ground cable.
- Loosen upper alternator T-bolt lock nut.
- Raise and support vehicle.
- Remove right front wheel.
- Remove accessory drive splash shield.
- Remove pencil strut.
- Loosen lower pivot bolt.
- Loosen accessory drive belt T-bolt.
- Unplug field circuit from alternator.
- Remove B+ terminal nut and wire.
- Remove alternator belt.
- Remove axle retaining nut.
- Remove lower control arm from steering knuckle.
- Remove axle shaft. Put a container under tr...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2005 Chrysler PT Cruiser AUTOMOBILES
Cabin Air Filter Service -> Chrysler LLC -> 2002-09 PT Cruiser
Vehicle: 2005 Chrysler PT Cruiser 2.4 L4 GAS
The cabin air filter should be replaced every 15,000 miles.
- Open the hood.
- Remove the passenger side cowl grille screen.
- Remove the three windshield washer reservoir to body attaching screws, then position the reservoir out of the way.
- Lift the cabin air filter eleme...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2005 Chrysler PT Cruiser AUTOMOBILES
Chrysler LLC Trucks -> Emission Maintenance Reminder Indicator -> Chrysler, Dodge & Plymouth
Vehicle: 2005 Chrysler PT Cruiser 2.4 L4 GAS
This Emission Maintenance Reminder System (Maintenance Required Lamp) is incorporated into the engine controller. The controller stores vehicle mileage into its memory every eight miles, then at 60,000, 82,500 or 120,000 miles it will light the EMR (Maintenance Required) lamp. When the indicated mileage is reached or the EMR lamp is on at all times, the following components must be replaced and the EMR lamp reset:
- At 60,00 miles, proceed as follows:
- Replace EGR valve.
- Clean EGR passage.
- Replace PCV valve.
- At 82,500 miles, replace oxygen sensor.
- At 120,000 miles, proceed as ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2005 Chrysler PT Cruiser AUTOMOBILES
Radiator, Replace
Vehicle: 2005 Chrysler PT Cruiser 2.4 L4 GAS
- Remove battery and battery tray.
- Drain cooling system into suitable container.
- Recover A/C refrigerant.
- Remove grille and upper radiator support crossmember.
- Remove upper radiator hose from radiator.
- Raise and support vehicle.
- Disconnect and cap automatic transmission cooler hoses.
- Disconnect radiator fan motor electrical connector.
- Remove lower radiator hose.
- Lower vehicle.
- Remove A/C lines ...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2005 Chrysler PT Cruiser AUTOMOBILES
Serpentine Drive Belt, Replace -> Alternator Belt -> Power Steering Belt & A/C Compressor Belt
Vehicle: 2005 Chrysler PT Cruiser 2.4 L4 GAS
Power Steering Belt & A/C Compressor Belt
- Remove right front splash shield.
- Release tension by rotating tensioner clockwise until belt can be removed from power steering pump pulley.
- Remove drive belt.
- Reverse procedur...
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COMPONENT LOCATION DIAGRAMS FOR 2005 Chrysler PT Cruiser AUTOMOBILES
Component location diagrams for most 2005 Chrysler PT Cruiser cars and light trucks sold in the U.S. from 1990+.
Data Link Connector Diagram for 2005 Chrysler PT Cruiser 2.4 L4 GAS Components on diagram: |
Powertrain Control Module Diagram for 2005 Chrysler PT Cruiser 2.4 L4 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 2005 Chrysler PT Cruiser AUTOMOBILES
OEM drawn wiring diagrams for most 2005 Chrysler PT Cruiser cars and light trucks sold in the U.S.
2005 Chrysler PT Cruiser 2.4 L4 GAS Wiring Diagram Components on diagram: |
2005 Chrysler PT Cruiser 2.4 L4 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2005 Chrysler PT Cruiser AUTOMOBILES
OEM TSB listings for most 2005 Chrysler PT Cruiser cars and light trucks sold in the U.S. from 1985+.
Document: Hard To Fill Or Fuel Nozzle Shuts Off Repeatedly Vehicle: 2005 Chrysler PT Cruiser 2.4 L4 GAS Auto Systems: |
Document: Chrome Clad Wheel Adapters For Proper Balancing Vehicle: 2005 Chrysler PT Cruiser 2.4 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2005 Chrysler PT Cruiser AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2005 Chrysler PT Cruiser cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2005 Chrysler PT Cruiser cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2005 Chrysler PT Cruiser cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2005 Chrysler PT Cruiser cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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