Chrysler JR Sebring 2004 Service Repair Workshop Manual

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This manual covers the Chrysler Sebring, a mid-size vehicle produced for the 2004 model year. Available in coupe, sedan, and convertible body styles, the Sebring was designed to offer distinctive American styling, comfort, and value to budget-conscious consumers. It was equipped with reliable V6 engine options, including a 2.7L and a more powerful 3.5L variant, paired with a 4-speed automatic transmission. The Sebring aimed to balance practicality with a stylish appearance, making it a competitive choice within its segment against rivals like the Toyota Camry and Honda Accord. This comprehensive Service and Repair Workshop Manual provides detailed guidance for maintaining and repairing the 2004 Chrysler Sebring. Its scope encompasses all major vehicle systems, including the engine mechanical and electrical components, automatic transmission, drivetrain, suspension, steering, brakes, electrical system, HVAC, body, and interior. The manual includes routine maintenance procedures, in-depth repair instructions, diagnostic troubleshooting, and technical specifications. It is an essential resource for owners, mechanics, and technicians to ensure the optimal performance, reliability, and longevity of the vehicle. 🏷️ Basic Information Identification Make: Chrysler Model: Sebring Year: 2004 Platform Code: JR Codes Chassis Code: JR 👋 Introduction Market Position Vehicle Segment: Mid-size car (coupe, sedan, convertible) Target Audience: Budget-conscious consumers seeking a practical and stylish American car. Competitive Analysis Key Competitors 2004: Ford Fusion, Chevrolet Malibu, Toyota Camry, Honda Accord, Nissan Altima, Volkswagen Passat Key Features Styling: Distinctive American styling, available in coupe, sedan, and convertible body styles. Value Proposition: Offered a balance of comfort, features, and affordability within its class. Engine Options: Provided reliable and reasonably powerful V6 engine options. 📋 Manual Details Coverage Areas Vehicle Systems: Engine, Transmission (Automatic & Manual), Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Body & Chassis, Interior Components, Diagnostic Procedures, Maintenance Schedules, Troubleshooting Page Count Estimated Pages: 1500-2000 (estimated, typical for comprehensive workshop manuals) Manual Type Type: Service and Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, valvetrain, pistons, crankshaft, lubrication system, cooling system, fuel delivery (excluding pump replacement if integrated into tank assembly for some models), intake system, exhaust system, engine tuning and specifications Engine Electrical: Ignition system, starting system, charging system, engine control module (ECM) operation and diagnostic trouble codes (DTCs), sensors and actuators, wiring diagrams Transmission Automatic: Transmission operation, internal components, hydraulic control, shift solenoids, valve body, transmission control module (TCM), fluid specifications, refill procedures, diagnostic procedures Transmission Manual: Gearbox operation, clutch system (hydraulic), gear selection linkage, fluid specifications, refill procedures, overhaul (if applicable) Drivetrain: Front-wheel drive (FWD) system, drive shafts, CV joints, differential (integral to transmission), wheel bearings Suspension: Front suspension (MacPherson strut, control arms, ball joints, sway bar), rear suspension (independent or semi-independent depending on configuration), shock absorbers, springs, bushings, alignment specifications Steering: Power steering system (hydraulic), steering gear/rack and pinion, steering column, tie rod ends, power steering fluid type and capacity Brakes: Front disc brakes, rear disc or drum brakes (depending on trim/engine), brake calipers, rotors, pads, brake lines, master cylinder, ABS (Anti-lock Braking System) components and diagnostics, parking brake system Electrical System: Battery, starter motor, alternator, lighting (headlamps, taillamps, interior), fuses and relays, wiring harnesses, body control module (BCM) operation, power windows, power locks, mirrors, wipers, horn HVAC: Air conditioning system, heater core, blower motor, climate controls (manual or automatic), refrigerant type and charge, cabin air filter replacement Body Chassis: Body construction, doors, hood, trunk lid, bumpers, fenders, body panels, glass, exterior trim, structural components, rust prevention, chassis lubrication (if applicable) Interior Components: Seats, dashboard, center console, door panels, headliner, interior trim, airbags system (SRS - Supplemental Restraint System), seatbelts Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, cabin air filter replacement, spark plug replacement, coolant flushes, brake fluid replacement, transmission fluid service, power steering fluid service, tire rotation and pressure checks, battery maintenance Engine Repair: Engine tune-up, timing belt/chain inspection and replacement (if applicable), cylinder head removal and installation, piston and connecting rod service, crankshaft and bearing service, oil pump and pan service, cooling system diagnostics and repair, fuel injector testing and replacement, exhaust system repair Transmission Repair: Transmission fluid and filter change (automatic), transmission overhaul (automatic/manual), clutch replacement (manual), torque converter replacement, transmission control module diagnosis and replacement Suspension Steering Repair: Strut and shock absorber replacement, ball joint replacement, control arm bushing replacement, tie rod end replacement, wheel bearing replacement, power steering pump replacement, steering rack repair/replacement, wheel alignment procedure Brake System Repair: Brake pad and rotor replacement, brake caliper overhaul/replacement, brake line bleeding, master cylinder replacement, ABS sensor replacement, parking brake adjustment/repair Electrical System Repair: Battery testing and replacement, alternator testing and replacement, starter motor testing and replacement, fuse and relay troubleshooting, bulb replacement, wiring harness repair, power window/lock actuator replacement, sensor replacement (e.g., O2 sensors, crankshaft position sensor), ECM/BCM troubleshooting HVAC Repair: Refrigerant recharge, A/C compressor replacement,...

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Description

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Sebring

Year:

Platform Code:

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Segment:

Mid-size car (coupe, sedan, convertible)

Target Audience:

Budget-conscious consumers seeking a practical and stylish American car.

Competitive Analysis

Key Competitors 2004:

Ford Fusion, Chevrolet Malibu, Toyota Camry, Honda Accord, Nissan Altima, Volkswagen Passat

Key Features

Styling:

Distinctive American styling, available in coupe, sedan, and convertible body styles.

Value Proposition:

Offered a balance of comfort, features, and affordability within its class.

Engine Options:

Provided reliable and reasonably powerful V6 engine options.

📋 Manual Details

Coverage Areas

Vehicle Systems:

Engine, Transmission (Automatic & Manual), Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Body & Chassis, Interior Components, Diagnostic Procedures, Maintenance Schedules, Troubleshooting

Page Count

Estimated Pages:

1500-2000 (estimated, typical for comprehensive workshop manuals)

Manual Type

Type:

Service and Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, valvetrain, pistons, crankshaft, lubrication system, cooling system, fuel delivery (excluding pump replacement if integrated into tank assembly for some models), intake system, exhaust system, engine tuning and specifications

Engine Electrical:

Ignition system, starting system, charging system, engine control module (ECM) operation and diagnostic trouble codes (DTCs), sensors and actuators, wiring diagrams

Transmission Automatic:

Transmission operation, internal components, hydraulic control, shift solenoids, valve body, transmission control module (TCM), fluid specifications, refill procedures, diagnostic procedures

Transmission Manual:

Gearbox operation, clutch system (hydraulic), gear selection linkage, fluid specifications, refill procedures, overhaul (if applicable)

Drivetrain:

Front-wheel drive (FWD) system, drive shafts, CV joints, differential (integral to transmission), wheel bearings

Suspension:

Front suspension (MacPherson strut, control arms, ball joints, sway bar), rear suspension (independent or semi-independent depending on configuration), shock absorbers, springs, bushings, alignment specifications

Steering:

Power steering system (hydraulic), steering gear/rack and pinion, steering column, tie rod ends, power steering fluid type and capacity

Brakes:

Front disc brakes, rear disc or drum brakes (depending on trim/engine), brake calipers, rotors, pads, brake lines, master cylinder, ABS (Anti-lock Braking System) components and diagnostics, parking brake system

Electrical System:

Battery, starter motor, alternator, lighting (headlamps, taillamps, interior), fuses and relays, wiring harnesses, body control module (BCM) operation, power windows, power locks, mirrors, wipers, horn

HVAC:

Air conditioning system, heater core, blower motor, climate controls (manual or automatic), refrigerant type and charge, cabin air filter replacement

Body Chassis:

Body construction, doors, hood, trunk lid, bumpers, fenders, body panels, glass, exterior trim, structural components, rust prevention, chassis lubrication (if applicable)

Interior Components:

Seats, dashboard, center console, door panels, headliner, interior trim, airbags system (SRS - Supplemental Restraint System), seatbelts

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, cabin air filter replacement, spark plug replacement, coolant flushes, brake fluid replacement, transmission fluid service, power steering fluid service, tire rotation and pressure checks, battery maintenance

Engine Repair:

Engine tune-up, timing belt/chain inspection and replacement (if applicable), cylinder head removal and installation, piston and connecting rod service, crankshaft and bearing service, oil pump and pan service, cooling system diagnostics and repair, fuel injector testing and replacement, exhaust system repair

Transmission Repair:

Transmission fluid and filter change (automatic), transmission overhaul (automatic/manual), clutch replacement (manual), torque converter replacement, transmission control module diagnosis and replacement

Suspension Steering Repair:

Strut and shock absorber replacement, ball joint replacement, control arm bushing replacement, tie rod end replacement, wheel bearing replacement, power steering pump replacement, steering rack repair/replacement, wheel alignment procedure

Brake System Repair:

Brake pad and rotor replacement, brake caliper overhaul/replacement, brake line bleeding, master cylinder replacement, ABS sensor replacement, parking brake adjustment/repair

Electrical System Repair:

Battery testing and replacement, alternator testing and replacement, starter motor testing and replacement, fuse and relay troubleshooting, bulb replacement, wiring harness repair, power window/lock actuator replacement, sensor replacement (e.g., O2 sensors, crankshaft position sensor), ECM/BCM troubleshooting

HVAC Repair:

Refrigerant recharge, A/C compressor replacement, condenser replacement, evaporator replacement, blower motor replacement, heater core replacement, climate control module diagnosis

Body Exterior Repair:

Door panel removal and installation, bumper cover repair/replacement, fender replacement, hood/trunk lid adjustment, glass replacement (windshield, side glass), exterior trim replacement

Body Interior Repair:

Seat removal and installation, dashboard disassembly and reassembly, center console removal, airbag system safety precautions and component replacement (e.g., clock spring, modules), seatbelt replacement

Troubleshooting:

System-specific diagnostic flowcharts, common problem diagnosis (e.g., starting issues, poor performance, no heat/AC), intermittent fault diagnosis

Technical Depth

Diagnostic Capabilities:

Advanced diagnostics including wiring diagrams, sensor data interpretation, DTC code explanation, and troubleshooting trees for complex electrical and mechanical issues.

Repair Scope:

From basic maintenance and fluid changes to complete engine and transmission overhauls, suspension rebuilds, brake system repairs, and complex electrical system diagnostics and component replacement.

Rebuild Procedures:

Detailed step-by-step instructions for component disassembly, inspection, repair, and reassembly, including torque specifications and clearances.

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text content for quick information retrieval.

Printability:

Printable pages for on-the-job reference.

Print Quality

Image Resolution:

High-resolution diagrams, illustrations, and photographs.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Code Common:

EDZ (2.7L V6)

Engine Displacement Primary:

2.7 Liters (167 cu in)

Engine Type Primary:

SOHC V6

Bore Stroke Primary:

86.0 mm x 78.0 mm (approx.)

Compression Ratio Primary:

9.7:1 (approx.)

Horsepower Primary:

180 hp @ 5800 rpm (approx.)

Torque Primary:

190 lb-ft @ 4200 rpm (approx.)

Secondary Engine

Engine Code Available:

EGD (3.5L V6)

Engine Displacement Secondary:

3.5 Liters (215 cu in)

Engine Type Secondary:

SOHC V6

Horsepower Secondary:

225 hp @ 5800 rpm (approx.)

Torque Secondary:

235 lb-ft @ 4000 rpm (approx.)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (MPI)

Recommended Fuel:

87 Octane Unleaded Gasoline (91 Octane recommended for optimal performance)

Cooling System

Coolant Type:

HOAT (Hybrid Organic Acid Technology) or equivalent extended life coolant (Chrysler HOAT Blue or equivalent)

Lubrication System

Oil Capacity:

4.5 Quarts (4.3 Liters) with filter change for 2.7L V6; 5.0 Quarts (4.7 Liters) with filter change for 3.5L V6 (approx.)

Recommended Oil Viscosity:

SAE 5W-30 (check owner's manual for specific climate conditions)

🔧 Transmission

Standard

Automatic Transmission Standard:

42RLE 4-speed automatic

Optional

Manual Transmission Available:

No manual transmission option for the JR Sebring in North America.

Features

Automatic Transmission Features:

Electronically controlled, adaptive shifting, torque converter lock-up

Fluid Specifications

Automatic Transmission Fluid:

ATF+4 (MS-9602) or equivalent Mopar specification fluid

Fluid Capacity

Automatic Transmission Fluid Capacity:

Approximately 6.0 Quarts (5.7 Liters) for a fluid and filter change (check dipstick)

📐 Dimensions

Exterior

Length:

Sedan: 193.7 inches (4919 mm); Coupe: 190.5 inches (4839 mm); Convertible: 188.2 inches (4780 mm) (approx.)

Width:

71.7 inches (1821 mm) (approx.)

Height:

Sedan: 56.8 inches (1443 mm); Coupe: 53.6 inches (1361 mm); Convertible: 54.1 inches (1374 mm) (approx.)

Wheelbase

Wheelbase:

109.7 inches (2786 mm) (approx.)

Weights

Curb Weight:

Approx. 3300-3600 lbs (1497-1633 kg) depending on body style and engine

Cargo

Trunk Volume:

Sedan: 15.5 cu ft; Coupe: 13.0 cu ft; Convertible (top up): 7.1 cu ft (approx.)

🛡️ Safety Features

Ratings

NHTSA Frontal Crash Test:

5-star driver, 4-star passenger (for sedan models in some tests)

IIHS Crash Test Ratings:

Good to Acceptable depending on specific test category and year.

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional Traction Control System (TCS)

Passive Features

Airbags Front:

Driver and front passenger airbags

Airbags Side:

Optional front side-impact airbags

Seatbelts:

Three-point seatbelts with pretensioners

Rollover Protection:

Pop-up rollover protection bars (convertible models)

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with CD player, optional premium audio systems (e.g., Infinity).

Display:

Basic dashboard display for audio and climate controls. No integrated navigation or large color screens available on base models.

Driver Assistance

Cruise Control:

Standard cruise control.

Parking Assist:

Not typically available for this model year.

Connectivity

Auxiliary Input:

Not standard; some aftermarket head units may add this feature.

Bluetooth:

Not available from the factory for this model year.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months (severe vs. normal driving), or based on oil life monitoring system if equipped.

Engine Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.

Cabin Air Filter Replacement:

Every 10,000-15,000 miles (16,000-24,000 km) or annually.

Spark Plug Replacement:

Every 30,000-60,000 miles (48,000-96,000 km) depending on plug type (e.g., platinum/iridium recommended).

Transmission Fluid Change:

Every 30,000-50,000 miles (48,000-80,000 km) for automatic transmission service (fluid and filter).

Coolant Replacement:

Every 30,000-50,000 miles (48,000-80,000 km) or every 3-5 years for HOAT coolant.

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4 (check owner's manual for specific recommendation)

Power Steering Fluid Type:

ATF+4 (MS-9602) or equivalent power steering fluid

Known Issues

Engine Performance 2.7L:

Potential for sludge buildup if oil changes are neglected, coolant leaks from intake manifold gaskets or heater hoses.

Transmission Issues:

Occasional shifting complaints or transmission slippage, often related to fluid condition or solenoid issues in the 42RLE.

Suspension Components:

Wear in ball joints, tie rod ends, and control arm bushings can lead to steering looseness and noise.

Electrical Gremlins:

Water intrusion into the TIPM (Totally Integrated Power Module) or other control modules can cause various electrical issues.

Climate Control:

HVAC blower motor failure, blend door actuator malfunctions, or leaks in the AC system.

📚 Vehicle History

Brand Heritage

Chrysler Legacy:

Chrysler has a long history of producing American-style sedans and coupes known for comfort and value.

Model Evolution

Sebring Generations:

The JR Sebring represents the second generation, launched in 2001 and facelifted for 2004. It was based on the Chrysler/Dodge platform shared with the Stratus. The subsequent generation (JS) was introduced for the 2007 model year.

Production

Manufacturing Location:

Sterling Heights, Michigan, USA

Production Years Jr Platform:

2001-2006

🏆 Awards & Recognition

Recognitions

Typical Awards:

Generally did not receive major industry awards but was a strong contender in the affordable mid-size segment.

Ratings

Consumer Satisfaction:

Mixed to average consumer satisfaction ratings, often dependent on maintenance and specific model year updates.

Certifications

Epa Fuel Economy:

EPA estimates for 2.7L V6: approx. 19 MPG city / 26 MPG highway; 3.5L V6: approx. 18 MPG city / 25 MPG highway (varies by body style and driving conditions).