Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHRYSLER2004PT CRUISER TOURING, 2.4 B, AUTOMATICREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE MECHANICALSTARTERSTARTING SYSTEMREMOVAL & INSTALLATIONSTARTER MOTORINSTALLATION - 2.2L DIESEL
2004 Chrysler PT Cruiser Touring, 2.4 B, Automatic
Installation - 2.2L Diesel
2004 Chrysler PT Cruiser Touring, 2.4 B, AutomaticSECTION Installation - 2.2L Diesel
- Install starter. See Figure .
- Install the upper mounting bolt.
- Install the lower mounting bolt and ground cable.
- Connect the battery cable to the starter. See Figure .
- Connect the electrical connectors to the starter. See Figure .
- Install the radiator to vehicle.
- Install radiator to inner cooler, make sure the 2 lower mounting tabs lock into the radiator brackets. These tabs are on the bottom of the inner cooler and lock into the bottom of the radiator. See Figure .
- Install the 4 upper bolts for the inner cooler mounting to radiator.
- Connect the electrical connector for the radiator fan.
- Install the upper radiator hose.
- Raise vehicle and support.
- Install the 2 lower bolts for the inner cooler mounting to radiator.
- Install the lower radiator hose.
- Install the underbody plate (skid plate), refer to the Body section for more information.
- Lower vehicle.
- Install ambient temperature sensor.
- Install the upper radiator crossmember.
- Install the hood seal, refer to the Body section for more information.
- Install the front grill, refer to the Body section for more information.
- Connect the negative battery cable.
- Fill radiator, refer to the Cooling section for more information.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.