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Chrysler PT Cruiser. Manual - part 942

SUNROOF DIAGNOSIS CHART

SYMPTOM

POSSIBLE CAUSE

Sunroof motor inoperative.

Faulty control switch.

Faulty circuit ground between sunroof electronics module, control
switch, and body harness.

Faulty power circuit between sunroof electronics module, control
switch, and body harness.

Faulty sunroof drive motor.

Faulty sunroof electronics module.

Faulty sunroof drive motor or electronics module.

Audible whine when switch is depressed,
sunroof does not operate.

Faulty sunroof drive motor.

Binding cable.

Audible clicking or ratcheting when switch is
pressed, sunroof does not operate.

Broken or worn drive cable.

Worn drive motor gear.

Mechanisms not synchronized.

Sunroof vents and opens, but does not
close.

Broken or disengaged trough guide

Binding cable.

Faulty circuit.

Faulty control switch.

Faulty sunroof electronic module.

Faulty drive motor.

Sunroof vents, but does not open.

Binding cable or mechanism.

Faulty circuit.

Faulty switch.

Faulty sunroof electronic module.

Sunroof does not vent

Binding cable or mechanism.

Faulty circuit.

Faulty control switch.

Faulty sunroof electronic module.

Sunroof water leak.

Drain tubes clogged or kinked or disconnected from the sunroof.

Glass panel improperly adjusted.

Faulty glass panel seal.

Gurgling sound from sunroof

Low spot in drain hose routing, allowing water to stand.

Wind noise from sunroof.

Front of glass panel too high or rear too low.

Wind deflector not deploying.

Glass not centered in opening.

Faulty glass panel seal.

Rattles from open sunroof while driving

Loose or broken attaching hardware.

Worn or broken mechanism.

23 - 226

SUNROOF

SUNROOF (Continued)

WATER DRAINAGE AND WIND NOISE DIAGNOSIS

The sliding glass panel is designed to seal water

entry with a snug fit between the roof and the seal.
The fit can be checked by inserting a piece of paper
between the roof and the seal. The piece of paper
should have some resistance when pulled out when
the glass panel is in the closed position. The sunroof
housing will drain off a minimum amount of water.
Excessive wind noise could result if the gap clear-
ances are exceeded. The sunroof glass panel may
need to be adjusted. Refer to Sunroof Glass Panel
Adjustment for proper procedures.

Adequate drainage is provided by a drain trough in

the sunroof housing which encircles the sliding glass
panel and leads to drain hoses. If a wet headliner or
other water leak complaints are encountered, before
performing any adjustments, first ensure that the
drainage system is not plugged or disconnected. Use
a pint container to pour water into the sunroof hous-
ing drain trough. If water flow is restricted, use com-
pressed air to blow out any material plugging the
drain system. Retest system again.

To further check for a disconnected drain hose:
(1) Remove A-pillar trim, sun visors, and map

lamps/mini console.

(2) Remove sunroof opening trim lace. Refer to

Sunroof Opening Trim Lace.

(3) Lower headliner as necessary to gain access to

sunroof housing drain tubes. Refer to Headlining
Removal and Installation for proper procedures.

(4) Repair as necessary.

SUNROOF MODULE
ASSEMBLY - VEHICLES BUILT
BEFORE 9/23/02

REMOVAL- VEHICLES BUILT BEFORE 9/23/02

(1) Move glass panel to the fully closed position.
(2) Disconnect battery negative cable.
(3) Recline both front seats.
(4) Remove sunroof opening trim lace (Refer to 23

BODY/SUNROOF/OPENING

TRIM

LACE

REMOVAL).

(5) Remove control switch (Refer to 23 - BODY/

SUNROOF/CONTROL SWITCH - REMOVAL).

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

RIOR/HEADLINER - REMOVAL) and disconnect
sunroof wire harness.

(7) Disconnect the four drain tubes from sunroof

housing.

(8) Loosen fasteners attaching sunroof module

assembly.

(9) Remove the two bracket screws at the rear of

the module.

(10) With the aid of a helper, support the sunroof

and remove the remaining six fasteners attaching
sunroof module assembly to roof panel (Fig. 1).

(11) Remove sunroof module from vehicle.

INSTALLATION- VEHICLES BUILT BEFORE
9/23/02

(1) Raise sunroof module assembly and guide it

carefully into position.

(2) While supporting the sunroof module tighten

the six module attaching screws (Fig. 1). Tighten to
9.5 N·m (84 in. lbs.) torque.

(3) Install the two bracket screws at the rear of

the module. Tighten to 9.5 N·m (84 in. lbs.) torque.

(4) Connect the drain tubes to the sunroof.
(5) Connect wire harness.
(6) Install headliner (Refer to 23 - BODY/INTERI-

OR/HEADLINER - INSTALLATION).

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

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

(8) Connect battery negative cable.
(9) Test sunroof operation, adjust as necessary

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

(10) Install sunroof opening trim lace position

(Refer to 23 - BODY/SUNROOF/OPENING TRIM
LACE - INSTALLATION).

SUNROOF

23 - 227

SUNROOF (Continued)

ELECTRONIC CONTROL
MODULE - VEHICLE BUILT
BEFORE 9/10/02

REMOVAL

(1) Remove sunroof module assembly (Refer to 23 -

BODY/SUNROOF/MODULE

ASSEMBLY

REMOVAL).

(2) Cut wire retaining tape near motor being care-

ful not to cut wires.

(3) Disconnect drive motor’s wire harness.
(4) Remove three motor assembly retaining screws

from bottom side of motor, and remove motor assem-
bly (Fig. 2).

(5) From top side of module assembly, remove one

attaching screw from control module.

(6) Disconnect the two wire connectors from elec-

tronic control module assembly.

(7) Remove control module.

INSTALLATION

(1) Check glass assembly position. Adjust to full

closed position. Insert pin into holes in lift arm
assembly to check position (Fig. 3).

(2) Check electronics module and ensure it’s in the

full closed position.

(3) Set new electronic module in position on top

side of motor mounting bracket engaging drive cables
with pinion gear in electronics module.

(4) Install one screw to attach electronics module

to motor bracket. Tighten screw to 3 N·m (27 in. lbs.)
torque.

(5) Install motor assembly to motor bracket and

electronics module with three screws. Tighten screw
to 3 N·m (27 in. lbs.) torque.

(6) Connect electrical connectors to module assem-

bly wire harness. Secure any loose wires.

Fig. 1 SUNROOF MODULE ASSEMBLY

1 - SUNROOF WIRING CONNECTOR
2 - SIDE RAIL

3 - SUNROOF MODULE

Fig. 2 CONTROL MODULE

1 - MOTOR BRACKET
2 - CABLES
3 - SCREW
4 - CONTROL MODULE

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SUNROOF

SUNROOF MODULE ASSEMBLY - VEHICLES BUILT BEFORE 9/23/02 (Continued)

(7) Install sunroof module assembly (Refer to 23 -

BODY/SUNROOF/MODULE ASSEMBLY - INSTAL-
LATION).

SUNROOF DRIVE MOTOR

REMOVAL

(1) Remove sunroof opening trim lace (Refer to 23

BODY/SUNROOF/OPENING

TRIM

LACE

REMOVAL).

(2) Remove sunroof control switch (Refer to 23 -

BODY/SUNROOF/CONTROL

SWITCH

REMOVAL).

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

RIOR/HEADLINER - REMOVAL) and disconnect
sunroof wire connector.

(4) Cut wire retaining tape near motor being care-

ful not to cut wires.

(5) Disengage wire harness from motor (Fig. 4).
(6) Remove three motor assembly attaching screws

from bottom side of motor assembly.

(7) Remove motor assembly.

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

(1) Remove headliner. (Refer to 23 - BODY/INTE-

RIOR/HEADLINER - REMOVAL)

(2) Disconnect the electrical connector (Fig. 5).

(3) Remove three motor assembly attaching screws

from bottom side of motor assembly.

(4) Remove

motor

assembly

from

the

motor

bracket.

Fig. 3 LIFT ARM POSITIONING

1 - GLASS BRACKET
2 - LIFT ARM
3 - ALIGNMENT PIN

Fig. 4 DRIVE MOTOR ASSEMBLY

1 - CONTROL MODULE
2 - SCREWS
3 - DRIVE MOTOR
4 - SCREW
5 - ELECTRICAL CONNECTOR

Fig. 5 DRIVE MOTOR

1 - ELECTRICAL CONNECTOR
2 - MODULE ASSEMBLY
3 - DRIVE MOTOR
4 - MOUNTING SCREWS

SUNROOF

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ELECTRONIC CONTROL MODULE - VEHICLE BUILT BEFORE 9/10/02 (Continued)

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