Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2002 Chrysler PT Cruiser owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2002 Chrysler PT Cruiser. The contact stated that while driving at 35 MPH, she could smell fuel in the interior of the vehicle. No warning lights were illuminated. The vehicle was taken to the dealer, who located a fuel leak on the fuel trail line. The vehicle was not repaired. After investigating the failure, the contact related the failure to NHTSA Campaign Number: 02V215000 (Fuel System, Gasoline) but the VIN was not included. The manufacturer was not notified of the failure. The failure mileage was 138,000.
While driving the vehicle I could begin to smell a strong odor of gas them almost like the smell of plastic melting and the vehicle engine started running hot temperature so I immediately turned off the engine as I pulled over to the side of the road and as I stepped out of the car aflame began under the hood and ended up burning my entire engine. Fire department had to come and extinguish the car.
While driving in reverse at approximately 3 MPH, the driver was warned by pedestrians that the vehicle was on fire. The driver exited the vehicle and a strong smell of gasoline could be detected. The driver opened the hood and there was a rush of flames, which died down after a second. The fire appeared to originate at the low center of the fire wall at the fuel line, which is located near the catalytic converter. Orlando fire department report stated the fire was due to a fuel leak.
Buyback request: my 2002 PT Cruiser was bought new, with an extended warranty. It was disabled by foothill Chrysler ' Jeep in foothill ranch ca, while performing a factory recall. It has not been used since then, because it is illegal to drive it. I took it in for 60K mile maintenance ($399). The mechanic demanded that I allow them to do a recall for the 'secondary fuel pump seal', which they did incorrectly, so the red 'check engine' light refused to shut off. The car will not pass the california smog requirement. Chrysler was then sold to Fiat, and foothill ranch Chrysler Jeep then went out of business, before they were able to fix it. My vehicle has been disabled, and has been stored on my driveway since 2009, where the neighbors have been complaining. The dealer had insisted that they fix a recall. I declined three times, then reluctantly said yes. …
Tl contact owns a 2002 Chrysler PT Cruiser. The contact stated that when the check engine light came on, the vehicle began to malfunction. The vehicle was also burning oil and leaking fuel excessively. The speedometer displayed that the speed was 70 MPH while the vehicle was in the park position. When the contact tried to shift gears from reverse into the park position, she had to put the vehicle in drive and then reverse. The dealer stated that the input/output speed sensor, third gear ratio and the fuel pump mounting flange on the vehicle malfunctioned. The dealer also stated that NHTSA recall campaign number 02V215000, fuel system and recall campaign number 01V288000 for the electrical system; did not apply to her VIN. The failure mileage was 85000 and the current mileage was 98100.
I had a very alarming incident on January 23, 2006. After filling the fuel tank and traveling approximately 20 miles I smelled a strong gasoline odor. I stopped the vehicle and looked to be sure the fuel cap was in place. It was so I attempted to re-start the engine. After several attempts the engine started but ran quite roughly. I again stopped the engine to check the source of the gasoline odor. When I looked at the rear of the vehicle gasoline was running over the edge of the fuel tank shield. I decided that the vehicle should not be started again because of the risk of fire or explosion. I had to have the vehicle towed to the dealers service center. I was told the fuel line was broken. I asked that the fuel line be saved for me. I have it and it is broken on the end.
The vehicle was in a significant rear end accident on 5/20/2002. It was repaired and returned after more than a month. Upon return the gas milage went to 13 mpg and the car would have a gas smell coming through the vents after a long idle or short stop. The dealer checked the fuel system and couldn't find any problem. Upon reading Chrysler's fuel pump defect recall for an indident discovered in an accident, our situation appears strickingly similar. Chrysler reports no prior complaints because their service people cannot identify the problem! I hope the car does not blow up on us in its present condition!!!
When first cranking ca rit will rev itself up, the speedometer goes to 120mph rpms tachs out, and then drops below 1/2 RPM, sputters and backfire soff. Had in Chrysler dealership 3 times for this and unable to find a problem. Told me that a sensor could be going bad. Now while my mother was driving out of neighborhood the car went dead as does with me at times at stop sign and refused to crank again. Called roadside had it for a charge of 75.00 and was told I had bad gas and wanted another 510.00 to fix. Was told not covered under reg. Warranty or the 1300.00 extended bumper to bumper we purchased.
Upon starting the vehicle consumer noticed that gas gauge was on empty. Consumer then took the vehicle to a gas station and filled the gas tank but the gas gauge still was on empty when the vehicle was restarted. Vehicle was then taken to a repair shop. Mechanic indicated that when the vehicle got hot from the sun the dashboard components become inoperative. When this occurred the driver was unable to determine the speed he was driving, and how much fuel was in the gas tank.
Driving to work this morning on the interstate at 75 MPH, with no indication or warning my 2002 chystler PT Cruiser completely shut down, steering wheel locked up. After I pulled over on the side of the road the car would no longer turn over or act like it wanted to start up. I then have the car towed to a mechanic shop near my home and was informed today my fuel pump went out.
Related recalls
Fuel system, gasoline › Delivery
On certain passenger vehicles, the fuel pump module mounting flange could leak fuel if the vehicle is involved in a rollover crash.
Remedy: Dealers will install a secondary seal over the fuel pump module. Owner notification began August 12, 2002. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the…
Fuel System complaints in other PT Cruiser years
Frequently asked questions
How common are fuel system problems on the 2002 Chrysler PT Cruiser?
NHTSA has 20 complaints about the fuel & propulsion system of the 2002 Chrysler PT Cruiser, 4% of the model year's 511 complaints. The component named most often is delivery › hoses, lines/piping, and fittings (6 mentions).
Is there a recall for 2002 Chrysler PT Cruiser fuel system problems?
Yes — NHTSA recall 02V-215 (delivery, Aug 8, 2002). Recall repairs are free at authorized dealers.
At what mileage do 2002 Chrysler PT Cruiser fuel system problems start?
Half of the complaints with a recorded mileage happened before about 47,000 miles, and 18% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 3 fires and 0 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.