Chrysler PT Cruiser. Manual - part 943

INSTALLATION

(1) Place motor into position (Fig. 4).
(2) Install three screws attaching motor to bracket.

Tighten screws to 3 N·m (27 in. lbs.) torque.

NOTE: Hold electronics module to motor bracket
when inserting motor shaft to avoid disengaging
drive cables.

(3) Connect sunroof electrical connector.
(4) Tape wires to drive cables to prevent rattles.
(5) Install headliner (Refer to 23 - BODY/INTERI-

OR/HEADLINER - INSTALLATION).

(6) Install sunroof control switch (Refer to 23 -

BODY/SUNROOF/CONTROL SWITCH - INSTALLA-
TION).

(7) Test sunroof operation, adjust sunroof glass as

necessary (Refer to 23 - BODY/SUNROOF/GLASS
PANEL - INSTALLATION).

(8) Install sunroof opening lace (Refer to 23 -

BODY/SUNROOF/OPENING TRIM LACE - INSTAL-
LATION).

INSTALLATION - VEHICLES BUILT ON 9/23/02
AND LATER

(1) If sunroof was open when drive motor was

removed, carefully move glass panel into closed posi-
tion and remove glass panel. (Refer to 23 - BODY/
SUNROOF/GLASS PANEL - REMOVAL)

(2) Set lifter arm timing by manually sliding the

mechanisms in the track until timing holes in the
trollies are aligned with the timing holes in the lifter
arm cams and insert pins into the mechanisms to
hold mechanisms in closed position. (Fig. 6)

(3) Place motor into position and install screws

attaching motor to bracket.

(4) Tighten the screws to 3 N·m (26 in. lbs.).
(5) If sunroof glass panel was removed previously,

remove the timing pins and install the sunroof glass
panel.

(Refer

BODY/SUNROOF/GLASS

PANEL - INSTALLATION)

(6) Temporarily install sunroof switch and perform

the sunroof motor teach procedure. (Refer to 23 -
BODY/SUNROOF/DRIVE

MOTOR

STANDARD

PROCEDURE - TEACH PROCEDURE)

(7) Test sunroof operation, adjust glass as neces-

sary. (Refer to 23 - BODY/SUNROOF/GLASS PANEL
- ADJUSTMENTS)

(8) Install headliner. (Refer to 23 - BODY/INTERI-

OR/HEADLINER - INSTALLATION)

SUNROOF CONTROL SWITCH

REMOVAL

(1) Using a flat blade tool, release switch from the

headliner.

(2) Disconnect the wire connector from the control

switch.

INSTALLATION

(1) Connect the wire connector to the control

switch.

(2) Install control switch into headliner.
(3) Test sunroof operation.

WIND DEFLECTOR

REMOVAL

(1) Fully open sunroof glass panel.
(2) Remove two screws attaching wind deflector

straps to front crossmember (Fig. 7).

(3) Rotate wind deflector into the vertical, 90° to

the roof.

(4) Push wind deflector arms down and rearward

to disengage arms from spring hooks.

(5) Remove wind deflector.

INSTALLATION

(1) Place wind deflector in position 90° to roof.
(2) Push arms down and forward to engage spring

hooks.

(3) Rotate wind deflector forward into correct posi-

tion. Depress wind deflector down onto front cross-
member to check spring function.

Fig. 6 LIFT ARM POSITIONING

1 - LIFTER ARM
2 - TROLLEY
3 - ALIGNMENT PIN

23 - 230

SUNROOF

SUNROOF DRIVE MOTOR (Continued)

(4) Install two screw attaching wind deflector

straps to front crossmember (Fig. 7). Tighten screws
to 1 N·m (9 in. lbs.) torque.

GLASS PANEL

REMOVAL

(1) Move the glass panel to the closed position.
(2) Slide sunshade rearward to the open position.
(3) Remove the four glass panel screws (Fig. 8).
(4) Lift off glass panel and remove from vehicle.

INSTALLATION

(1) Position glass panel on to mechanism lift arms.
(2) Start the four attaching screws, do not fully

tighten (Fig. 8).

(3) Adjust sunroof glass (Refer to 23 - BODY/SUN-

ROOF/GLASS PANEL - ADJUSTMENTS).

(4) Verify sunroof operation and alignment.

ADJUSTMENTS

SUNROOF GLASS PANEL ADJUSTMENT

(1) Move the sunshade rearward to the open posi-

tion.

(2) Move the sunroof glass panel to the fully closed

position.

(3) Loosen the forward attaching screws on each

side enough to make the front of the glass to adjust
up or down (Fig. 8).

(4) Adjust the front surface of the sunroof glass

panel 1.75 mm to 2.75 mm (0.07 in. to 0.11 in.) below
the top surface of the roof.

NOTE: Top of the glass seal is 2.5 mm (0.1 in.)
higher than the surface of the sunroof glass. Mea-
sure at 300 mm (11.8 in.) outboard of the center line
of the vehicle.

(5) Tighten the front glass panel attaching two

screws to 3.5 N·m (31 in. lbs.) torque (Fig. 8).

(6) Loosen the rear screws on each side enough to

make the rear adjustment (Fig. 8).

(7) Adjust the rear surface of the sunroof glass

panel 0.75 mm to .75 mm (0.03 in. to 0.07 in.) below
the top surface of the roof.

(8) Tighten the rear glass panel attaching two

screws to 3.5 N·m (31 in. lbs.) torque (Fig. 8).

(9) Check for proper fit. If not OK, repeat glass

panel adjustment.

SUNROOF SUNSHADE

REMOVAL

(1) Remove sunroof glass panel (Refer to 23 -

BODY/SUNROOF/GLASS PANEL - REMOVAL).

(2) From the top of the vehicle through the roof

opening remove the two screws (one LH and one RH
side) attaching trough assembly to trough guides
(Fig. 9).

(3) Remove trough assembly.

Fig. 7 SUNSHADE

1 - WIND DEFLECTOR
2 - SCREW
3 - SPRING

Fig. 8 GLASS PANEL

1 - SCREWS
2 - GLASS PANEL
3 - MODULE ASSEMBLY

SUNROOF

23 - 231

WIND DEFLECTOR (Continued)

(4) From the top of the vehicle through roof open-

ing slide the sunshade forward, disengaging sun-
shade front guide feet through front opening in
tracks.

(5) Continue to pull the sunshade forward and

rotate sunshade until rear guide feet are disengaged
from tracks and sunshade is completely free from the
sunroof assembly.

CAUTION: Use care not to crease the sunshade
when removing or installing.

INSTALLATION

(1) From top of the vehicle through roof opening

place sunshade into position, rotating rear guide feet
of sunshade into opening of track.

(2) Guide front sunroof feet through front opening

and into the track grooves.

(3) Set trough assembly in position on sunroof

assembly. Ensure that the trough crosses over the
top of the sunshade.

(4) Install two screws attaching trough guide to

trough assembly. Tighten screw to 1 N·m (9 in. lbs.)
torque (Fig. 9).

SUNROOF GLASS PANEL SEAL

REMOVAL

(1) Remove sunroof glass panel (Refer to 23 -

BODY/SUNROOF/GLASS PANEL - REMOVAL).

(2) Place glass panel on a clean work area with the

top side up. Support the glass assembly from under
side to avoid bending or otherwise damaging the
mounting tabs.

(3) Grasp the seal and pull seal away from the

glass panel. The seal is a one piece seal.

INSTALLATION

NOTE: Always position seal seam on center side of
the passenger side of glass panel.

(1) Place seal into position.
(2) Install seal on glass panel. Using care working

the seal around the glass, being careful not to stretch
the seal while installing.

(3) Replace sunroof glass panel (Refer to 23 -

BODY/SUNROOF/GLASS

PANEL

INSTALLA-

TION).

(4) Verify sunroof operation and alignment (Refer

to 23 - BODY/SUNROOF/GLASS PANEL - ADJUST-
MENTS).

OPENING TRIM LACE

REMOVAL

(1) Remove lace by starting at the joint center of

the opening on driver’s side.

(2) Pull one end of the lace away from the head-

liner until the entire lace is removed.

INSTALLATION

(1) Place trim lace into position starting at center

of the opening on driver’s side.

(2) Push lace into position.
(3) Ensure that the corner radii is fully engage.
(4) Once trim lace is attached to sunroof module

begin tucking the headline under the lip on the trim
lace working all the way around the opening.

SUNROOF TROUGH GUIDE
ASSEMBLY

REMOVAL

(1) Remove the sunroof glass panel (Refer to 23 -

BODY/SUNROOF/GLASS PANEL - REMOVAL).

(2) Place sunroof into the vent position.
(3) Remove screws from the trough assembly one

on each side (Fig. 9).

(4) Remove trough.
(5) Disconnect the guide link (Fig. 10).
(6) Slide trough guide forward and disengage the

sliders through the notches in guide channels (Fig.
11).

Fig. 9 GUIDE ASSEMBLY TROUGH

1 - TROUGH
2 - TROUGH GUIDE
3 - SCREW

23 - 232

SUNROOF

SUNROOF SUNSHADE (Continued)

INSTALLATION

(1) Carefully twist trough guide through small slot

(cut out) on track to install (Fig. 11).

(2) Connect the trough guide wire to the lifter arm

(Fig. 10).

(3) Place the trough into position on sunroof.

Ensure that the trough crosses over the top of the
sunshade.

(4) Install the two screws that attach the trough to

the trough guides (Fig. 9). Tighten screws to 1 N·m
(9 in. lbs.) torque.

(5) Install sunroof glass panel (Refer to 23 -

BODY/SUNROOF/GLASS

PANEL

INSTALLA-

TION).

DRAIN TUBE

REMOVAL

FRONT DRAIN TUBE

(1) Move glass panel to the fully closed position.
(2) Remove sunroof opening trim lace (Refer to 23

BODY/SUNROOF/OPENING

TRIM

LACE

REMOVAL).

(3) Disconnect the control switch and wire connec-

tor.

(4) Remove headliner (Refer to 23 - BODY/INTE-

RIOR/HEADLINER - REMOVAL).

(5) Disconnect the drain tube from the sunroof

housing (Fig. 12).

(6) Drain any liquid from tube connection, if nec-

essary.

(7) Attach new drain tube to old tube with tape

that is to be replaced.

(8) Work the old tube back and forth to loosen the

sealer.

(9) Use care and pull the old tube out through the

bottom and the new tube through.

REAR HOUSING TUBE

(1) Move glass panel to the fully closed position.
(2) Remove sunroof opening trim lace (Refer to 23

BODY/SUNROOF/OPENING

TRIM

LACE

REMOVAL).

(3) Disconnect the control switch and wire connec-

tor.

(4) Remove headliner (Refer to 23 - BODY/INTE-

RIOR/HEADLINER - REMOVAL).

(5) Disconnect the drain tube from the sunroof

housing (Fig. 13).

(6) Drain any liquid from tube connection, if nec-

essary.

(7) Attach new drain tube to old tube with tape

that is to be replaced.

(8) Work the old tube back and forth to loosen the

sealer.

(9) Use care and pull the old tube out through the

bottom and the new tube through.

INSTALLATION

FRONT TUBE

(1) Connect the new drain tube to the sunroof

housing and test drainage (Fig. 12).

(2) Install headliner (Refer to 23 - BODY/INTERI-

OR/HEADLINER - INSTALLATION).

(3) Install sunroof opening trim lace (Refer to 23 -

BODY/SUNROOF/OPENING TRIM LACE - INSTAL-
LATION).

(4) Connect the control switch wire connector and

install control switch.

Fig. 10 TROUGH GUIDES

1 - TROUGH GUIDE
2 - GUIDE LINK

Fig. 11 TROUGH GUIDE REMOVAL

1 - TROUGH GUIDE
2 - NOTCH
3 - SLIDER

SUNROOF

23 - 233

SUNROOF TROUGH GUIDE ASSEMBLY (Continued)

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