2001–2006 Chrysler Sebring Service Manual (P/N 81-270-02025)

• Exact factory coverage: 2002 and 2004 Chrysler Sebring sedans and convertibles, plus Dodge Stratus sedans, on the JR41/JR27 platform. Sebring and Stratus coupes are not covered, and this is not an all-year 2001-2006 manual.
• 6,284 PDF pages across 13 files: two model-year service manuals, separate factory body, chassis, and gas-powertrain diagnostic volumes for both years, a 2002 transmission diagnostic manual, a 2004 owner's manual, and supporting front matter. A three-page generic DTC sheet is separate from the factory material.
• Engine repair sections cover the 2.0L, 2.4L, and 2.7L DOHC engines, with engine removal and installation, cylinder-head and valvetrain work, timing-belt and timing-chain service, internal inspection, lubrication, cooling, fuel, and emissions procedures.
• Transmission and driveline work includes 41TE automatic diagnosis and internal repair, hydraulic and air checks, Quick Learn and clutch-volume routines, plus NV T350 and T850 manual-transaxle removal, disassembly, synchronizer service, differential setup, and reassembly.
• Chassis procedures address the SLA front and fully independent rear suspensions, shock assemblies, hubs, ball joints, alignment, base brakes, Teves Mark 20/20e ABS, traction control, steering, and hydraulic bleeding and testing.
• Electrical fault finding is supported by DRBIII decision trees, DTC test charts, verification tests, component locations, connector pinouts, wiring diagrams, and system schematics for powertrain, body, brake, restraint, HVAC, security, and convertible-top systems.

The factory service material was prepared for professional automotive technicians and assumes access to shop equipment, test instruments, and a DRBIII scan tool. Experienced owners can use the maintenance, specification, and owner's-manual sections, but advanced diagnosis, restraint-system work, engine repair, and transaxle rebuilding are shop-level jobs.

Model-Year and Configuration Detail

The 2002 material identifies ECC 2.0L, EDZ 2.4L, and EER 2.7L gasoline engines, along with the 41TE automatic and NV T350/T850 manual transaxles. Its dedicated 41TE/AE diagnostic volume covers JR41 sedans and JR27 convertibles, including Autostick where fitted, electronic pinion-factor setup, limp-in diagnosis, clutch-volume readings, and post-repair verification.

The 2004 powertrain book separates all 2.0L/2.4L NGC applications and late-launch 2.7L NGC vehicles from early-launch 2.7L SBEC control. It also covers PCM, Sentry Key Immobilizer Module, and ignition-key programming, fuel-delivery and leak-down tests, OBD driveability faults, connector views, and engine-specific schematics. The 2004 identification data lists the EDV 2.4L turbo and EEE 2.7L flexible-fuel codes; the files include FFV-specific fuel information but no dedicated turbocharger repair chapter. Only the 2002 set contains a standalone transmission diagnostic manual.

Repair and Diagnostic Depth

The main workshop manuals go well beyond maintenance data. Engine chapters cover compression and leakage diagnosis, cylinder-head removal, camshaft and valve service, piston and crankshaft inspection, oil-pump work, and the different timing layouts used by the four-cylinder and 2.7L engines. The 2.7L section includes the chain-driven water pump and primary/secondary timing-chain assemblies.

Body diagnostics trace faults through the PCI data bus, Body Control Module, staged airbag and side-impact systems, automatic and manual HVAC, instrument cluster, lighting, power locks, theft security, wipers, and the convertible power top/window-drop circuitry. Chassis diagnostic books add symptom-based DRBIII tests for the Controller Antilock Brake, wheel-speed circuits, hydraulic control unit, ABS pump and valves, traction control, and final verification. Mechanical brake chapters supply the related component repair and bleeding procedures.

Wiring, Specifications, and Shop Cautions

The 8W electrical sections include named diagrams for Bus Communications, Fuel/Ignition, Transmission Control, Antilock Brakes, Occupant Restraint, and Power Top, backed by connector, ground, and splice-location views. Component-specific torque tables, fluid types and capacities, pressure-test data, alignment specifications, electrical values, wear limits, and assembly clearances are organized within the relevant repair groups. The separate owner's manual adds operating instructions, emergency information, routine checks, scheduled maintenance, and 2.4L PZEV-specific service items.

Special-tool references include the Miller 8333 transmission simulator with 8333-1 FWD adapter, plus the Miller 3638 terminal pick and 8815 pinout box for 2004 NGC connector work. The powertrain diagnostic manual warns that incorrect terminal release or probing can damage the PCM harness connectors. The suspension chapter also cautions against drilling or installing metal fasteners in the marked shock-tower clearance area, where contact can damage the coil-spring coating and lead to spring failure. Before chassis or spring work, verify the specified frame-contact lift points, contain stored spring energy with the proper equipment, and use suitable personal protective equipment.