Chrysler PT Cruiser Control Arm Replacement in Kirkland, WA: Torn Bushings, Two Belt Tensioners and a Two-Code Check Engine Light

This 2003 Chrysler PT Cruiser GT, the turbocharged one with a manual gearbox, first came into our Kirkland shop in September for an oil change. Our multi-point inspection found more than oil to talk about. In October, at 88,924 miles, the owner brought it back and had us replace both front lower control arms, both belt tensioners and the drive belts, and run a full diagnosis on the check engine light.

What the September inspection found

The September visit was a basic oil service at 88,163 miles. The inspection that comes with it flagged:

• A control arm bushing tearing.

• The check engine light on, with two codes stored: P0441 (EVAP purge system performance) and P0325 (knock sensor 1 circuit).

• Oil leaks, including the oil pan.

• A sticky front right brake caliper.

The control arm bushing at the September inspection. The rubber is torn and bulging out of its sleeve.

We quoted the control arms, a belt and tensioner replacement, check engine diagnostics and an engine cleaning. The owner held off that day and came back in October to have them done.

The work performed

Front lower control arms and alignment: $1,150–$1,550. Both front lower control arms replaced with new arm and ball joint assemblies. The ball joints were separated from the knuckles, the old arms removed, the new ones installed and the ball joints reconnected. A partner shop did the four-wheel alignment afterward. Test drive OK. Steering and suspension repair and wheel alignment.

Belt tensioners and drive belts: $500–$700. We removed the right front fender liner, released the belt tension, and replaced both belt tensioners and both drive belts, then set the tension and reinstalled the liner. Test drive OK. Belt and hose replacement.

Engine cleaning for leak inspection: $40–$70. The engine had oil leaks. We cleaned off the oil so it can be inspected at a future visit.

Check engine light diagnostics: $150–$225. Engine diagnostics.

What the diagnosis found

P0325, knock sensor. Our technician checked the wiring and the signal at the sensor. The wiring was good, but the sensor had no signal output to the engine computer. The recommendation: replace the knock sensor.

P0441, EVAP purge system. We ran the diagnostic procedure for the tank leak detection system. It found multiple leaks on the intake and the EVAP system, and the purge valve stuck during testing.

A still from the technician’s video of the intake pipe. The diagnosis found multiple leaks on the intake side and recommended replacing this pipe.

What we recommended, but the owner held off on

The diagnosis led to one more quote, in the $1,350–$1,700 range:

• A new knock sensor

• A new intake pipe and the turbo bypass valve, for the intake leaks

• A new purge valve and a new leak detection pump (the NVLD), for the EVAP system

The owner held off on this for now. The September inspection’s sticky front right caliper also isn’t part of this visit.

What it cost

The October visit landed in the $2,000–$2,500 range, completed October 2026. The control arms and alignment were the biggest share, followed by the belt work, with the diagnosis and engine cleaning making up the rest.

That range reflects a completed historical project, not a current quote.

Questions about this job

Were both control arms replaced?

Yes. The September quote covered both front lower control arms, and both were replaced in October as complete arm and ball joint assemblies, followed by a four-wheel alignment.

Was the knock sensor wiring checked?

Yes. Our technician tested the wiring and the signal at the sensor before recommending a new sensor. The wiring was good; the sensor had no output.

Were the check engine codes fixed?

Not on this visit. The diagnosis was done and the repair was quoted, and the owner held off on it.

Do you work on Chrysler and Dodge vehicles?

Yes. More on our Chrysler repair in Kirkland.

Prepared from our job records for this vehicle: two repair orders and their technician notes, the diagnostic scan, the September multi-point inspection with photos, the inspection video, the parts list and the final invoice.