Chrysler PT Cruiser. Manual - part 941

INSTALLATION - PT-27 ONLY

CAUTION: Open the left front door glass before
installing windshield to avoid pressurizing the pas-
senger compartment. If a door is slammed before
urethane bonding is cured, water leaks can result.
Allow the urethane at least 24 hours to cure before
returning the vehicle to use.
To avoid stressing the replacement windshield, the
urethane bonding material on the windshield fence
should be smooth and consistent to the shape of
the replacement windshield. The support spacers
should be cleaned and properly installed on weld
studs or repair screws at bottom of windshield
opening.

Fig. 11 WINDSHIELD LOADING

1 - ENCAPSULATION LOCATOR PIN
2 - ENCAPSULATION HOOK

Fig. 12 URETHANE APPLICATION

1 - WINDSHIELD ASSEMBLY WITH ENCAPSULATION
2 - GLASS PRIMERS

3 - WINDSHIELD OPENING PRIMER
4 - URETHANE

23 - 222

STATIONARY GLASS

WINDSHIELD (Continued)

(1) Verify support spacers in windshield opening. If

not present, install spacers as indicated. (Fig. 14)

(2) Position windshield into opening by contacting

header spacers then loading the glass hooks onto the
panel hooks. (Fig. 15)

(3) Verify glass encapsulation lays evenly along

roof panel and that there is no gapping of the glass
to spacers in the windshield opening. If gaps are
present, the pinch weld fence must be formed to the
shape of the new glass.

(4) Remove replacement windshield from opening.
(5) Position the windshield inside up on a suitable

work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart. (Fig. 16)

WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER

CLEAN

WINDSHIELD

BEFORE

APPLYING

GLASS

PREP AND

PRIMER.

POOR

ADHESION CAN RESULT.

(6) Clean inside of windshield with ammonia based

glass cleaner and lint-free cloth.

(7) Apply Glass Prep adhesion promoter 25 mm (1

in.) wide around perimeter of windshield and wipe
with clean/dry lint-free cloth until no streaks are vis-
ible (Fig. 13).

(8) Apply Glass Primer 25 mm (1 in.) wide around

perimeter of windshield. Allow at least three minutes
drying time.

(9) Apply a bead of urethane on windshield glass

as indicated. (Fig. 16)

(10) With the aid of a helper, position the wind-

shield over the windshield opening and install con-
tacting header spacers then load glass hooks onto the
roof panel hooks.

(11) Push windshield into opening until there is

glass to spacers in the windshield opening

(12) Clean excess urethane from exterior with

Mopar, Super clean or equivalent.

(13) Apply

tape

windshield

assembly

required if gap exists around windshield opening.

(14) After urethane has cured, remove tape strips

and water test windshield to verify repair.

(15) Install cowl covers, A-pillar trim and header

trim molding.

(16) Install inside rear view mirror.
(17) Allow urethane to cured for 10 to 12 hours.

Remove tape strips and water test windshield.

Fig. 13 WINDSHIELD INSTALLATION

1- WINDSHIELD ASSEMBLY WITH ENCAPSULATION
2 - ENCAPSULATION SQUEAK REDUCTION TAPE
3 - ANTI-SQUEAK LUBRICANT

Fig. 14 WINDSHIELD SUPPORTS

1 - SUPPORT SPACERS ON ROOF PANEL (9mm X 20mm X
3mm)
2 - SUPPORT SPACERS ON COWL PANEL (9mm X 20mm X
6mm)
3 - ROOF PANEL HOOK
4 - ROOF PANEL SQUEAK REDUCTION TAPE

STATIONARY GLASS

23 - 223

WINDSHIELD (Continued)

Fig. 15 WINDSHIELD LOADING

1 - ENCAPSULATION LOCATOR PIN
2 - ENCAPSULATION HOOK

Fig. 16 URETHANE APPLICATION

1 - WINDSHIELD ASSEMBLY WITH ENCAPSULATION
2 - GLASS PRIMERS

3 - WINDSHIELD OPENING PRIMER
4 - URETHANE

23 - 224

STATIONARY GLASS

WINDSHIELD (Continued)

SUNROOF

TABLE OF CONTENTS

page

SUNROOF

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . 225

DIAGNOSIS AND TESTING - SUNROOF

. . . . . 225

SUNROOF MODULE ASSEMBLY - VEHICLES

BUILT BEFORE 9/23/02
REMOVAL- VEHICLES BUILT BEFORE 9/23/02

. 227

INSTALLATION- VEHICLES BUILT BEFORE

9/23/02

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

ELECTRONIC CONTROL MODULE - VEHICLE

BUILT BEFORE 9/10/02
REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 228

SUNROOF DRIVE MOTOR

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . 229

REMOVAL - VEHICLES BUILT ON 9/23/02

AND LATER . . . . . . . . . . . . . . . . . . . . . . . . . 229

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . 230

INSTALLATION - VEHICLES BUILT ON

9/23/02 AND LATER . . . . . . . . . . . . . . . . . . . 230

SUNROOF CONTROL SWITCH

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 230

WIND DEFLECTOR

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 230

GLASS PANEL

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 231

ADJUSTMENTS

SUNROOF GLASS PANEL ADJUSTMENT

. . 231

SUNROOF SUNSHADE

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 232

SUNROOF GLASS PANEL SEAL

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 232

OPENING TRIM LACE

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 232

SUNROOF TROUGH GUIDE ASSEMBLY

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 233

DRAIN TUBE

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 233

SUNROOF

DESCRIPTION

WARNING: Keep fingers and other body parts out
of sunroof opening at all times.

The sunroof features a power sliding glass panel

and a sunshade which can be manually positioned
anywhere along its travel, rearward of glass panel
front edge.

The sunroof is electrically operated from two

switches located on the windshield header, rearward
of the map lamp. To operate the sunroof the ignition
switch must be in either the Accessory or On/Run
position. One switch (vent) is a push button type and
opens the sunroof to the vent position only. The other
switch (open/close) is a rocker type for opening and
closing the sunroof. Pressing and releasing the open
button once the sunroof will express open and the
wind deflector will rise. If the button is pressed a
second time the sunroof will stop in that position.
Pressing and holding the close button will close the
sunroof. If the close button is released the sunroof
will stop in that position.

DIAGNOSIS AND TESTING - SUNROOF

Before beginning sunroof diagnostics verify that all

other power accessories are in proper operating con-
dition. Refer to Sunroof Diagnostic Chart for possible
causes. If not, a common electrical problem may
exist. Refer to Wiring Diagrams, in this publication
for circuit, splice and component descriptions. Check
the condition of the circuit protection (20 amp circuit
breaker in cavity 19 of the Junction Block). Inspect
all wiring connector pins for proper engagement and
continuity. Check for battery voltage at the power
sunroof controller, refer to Wiring Diagrams, for cir-
cuit information. If battery voltage of more than 10
volts is detected at the controller, proceed with the
following tests (the controller will not operate at less
than 10 volts).

Before beginning diagnosis for wind noise or water

leaks, verify that the problem was not caused by
releasing the control switch before the sunroof was
fully closed. The sunroof module has a water-man-
agement system. If however, the sunroof glass is in a
partial closed position, high pressure water may be
forced beyond the water management system bound-
aries and onto the headlining.

SUNROOF

23 - 225

Content .. 939 940 941 942 ..