Chrysler PT Cruiser. Manual — part 888
STANDARD PROCEDURE - HEAT STAKING
(1) Remove trim panel.
(2) Bend or move the trim panel components at
the heat staked joints. Observe the heat staked loca-
tions and/or component seams for looseness.
(3) Heat stake the components.
(a) If the heat staked or component seam loca-
tion is loose, hold the two components tightly
together and using a soldering gun with a flat tip,
melt
the
material
securing
the
components
together. Do not over heat the affected area, dam-
age to the exterior of the trim panel may occur.
(b) If the heat staked material is broken or miss-
ing, use a hot glue gun to apply new material to
the area to be repaired. The panels that are being
heat staked must be held together while the apply-
ing the glue. Once the new material is in place, it
may be necessary to use a soldering gun to melt
the newly applied material. Do not over heat the
affected area, damage to the exterior of the trim
panel may occur.
(4) Allow the repaired area to cool and verify the
repair.
(5) Install trim panel.
SPECIFICATIONS
BODY LUBRICATION
LUBRICATION REQUIREMENTS
Body
mechanisms
and
linkages
should
be
inspected, cleaned, and lubricated, as required, to
maintain ease of operation and to provide protection
against rust and wear. When performing other under
hood services, the hood latch release mechanism and
safety catch should be inspected, cleaned, and lubri-
cated. During the winter season, external door lock
cylinders should be lubricated to assure proper oper-
ation when exposed to water and ice.
Prior to the application of any lubricant, the parts
concerned should be wiped clean to remove dust and
grit. If necessary, a suitable solvent can be used to
clean the item to be lubricated. After lubricating a
component, any excess oil or grease should be
removed.
LUBRICANT APPLICATION
DOOR LOCK CYLINDERS
(1) Apply a small amount of lubricant directly into
the lock cylinder.
(2) Apply a small amount of lubricant to the key.
(3) Insert key into lock cylinder and cycle the
mechanism from the locked to the unlocked position.
NOTE: Do not add more lubricant.
(4) Cycle the lock cylinder mechanism several
times to allow the lubricant to flow throughout the
cylinder.
(5) Wipe all lubricant from exterior of lock cylinder
and key.
ALL OTHER BODY MECHANISMS
(1) Clean component as described above.
(2) Apply specified lubricant to all pivoting and
sliding contact areas of component.
Fig. 14 COVER GAPS WITH MESH
1 - GROUND DOWN AREA
2 - PATCH
3 - MESH
Fig. 15 COVER MESH WITH ADHESIVE
1 - ADHESIVE
2 - MESH
3 - PATCH
4 - SPREADER
23 - 10
BODY
PT
BODY (Continued)
LUBRICANT USAGE
ENGINE OIL
• Door Hinges – Hinge Pin and Pivot Contact
Areas
• Hood Hinges – Pivot Points
• Liftgate Hinges
MOPAR
T
SPRAY WHITE LUBE OR EQUIVALENT
• Door Check Straps
• Liftgate Latches
• Liftgate Prop Pivots
• Ash Receiver
• Fuel Filler Door Remote Control Latch Mecha-
nism
• Parking Brake Mechanism
• Sliding Seat Tracks
• Liftgate Latch
MOPAR
T
Multipurpose GREASE OR EQUIVALENT
• All Other Hood Mechanisms
MOPAR
T
LOCK CYLINDER LUBRICANT OR
EQUIVALENT
• Door Lock Cylinders
• Liftgate Lock Cylinder
SPECIFICATIONS - TORQUE
DESCRIPTION
N·m
Ft.
Lbs.
In.
Lbs.
All seat belt anchor bolts
40
N·m
30 ft.
lbs.
—
All seat belt anchor nuts
40
N·m
30 ft.
lbs.
—
All seat belt retractor bolts
40
N·m
30 ft.
lbs.
—
Liftgate latch striker
22
N·m
16 ft.
lbs.
—
DESCRIPTION
N·m
Ft.
Lbs.
In.
Lbs.
Front seat track to floor pan
bolts
55
N·m
40 ft.
lbs.
—
Front seat inboard pivot bolt
40
N·m
30 ft.
lbs.
—
Front seat recliner to seat
cushion frame
12
N·m
9 ft.
lbs.
—
Front seat track to cushion
frame bolt
12
N·m
9 ft.
lbs.
—
Front seat back
40
N·m
30 ft.
lbs.
—
Front seat back recliner to seat
back
12
N·m
9 ft.
lbs.
—
Front door hinge to hinge pillar
bolt
28
N·m
21 ft.
lbs.
—
Front door hinge to door nuts
and bolt
28
N·m
21 ft.
lbs.
—
Front door latch striker
28
N·m
20 ft.
lbs.
—
Hood latch striker
13.5
N·m
10 ft.
lbs.
—
Rear door glass to regulator
bolt
11
N·m
105
in.
lbs.
—
Rear door hinge to B-pillar bolt
28
N·m
20 ft.
lbs.
—
Rear door latch striker
28
N·m
20 ft.
lbs
—
Rear seat back and seat belt
buckle anchor nut
57
N·m
42 ft.
lbs.
—
PT
BODY
23 - 11
BODY (Continued)
SPECIAL TOOLS
BODY
INDEX
DESCRIPTION
FIGURE
STICK, TRIM C 4755
16
REMOVER, MOLDINGS C-4829
17
PLIERS, HEADLINER CLIP 6967
18
Fig. 16 STICK, TRIM C 4755
Fig. 17 REMOVER, MOLDINGS C-4829
Fig. 18 PLIERS, HEADLINER CLIP 6967
23 - 12
BODY
PT
BODY (Continued)
CONVERTIBLE TOP
TABLE OF CONTENTS
page
page
CONVERTIBLE TOP
. . . . . . . . . . . . . . . . . . . . . . . . 13
BACKLITE ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . . . . . . 14
FOLDING TOP ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . . . 18
FOLDING TOP COVER ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . . . . . . . . . 23
HEADLINER ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
. . . . . . . . . . . . . . . . . . . . . . . . . 29
MOTOR/HYDRAULIC PUMP ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
. . . . . . . . . . . . . . . . . . . . . . . . . 34
LATCH SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
. . . . . . . . . . . . . . . . . . . . . . . . . 36
RAIL SEALS-FRONT AND CENTER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . . . . . . . . . . . 37
RAIL SEALS-REAR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . . . . . . . . . . . 37
WIRE HARNESS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . . . . . . . . . . . 37
CONVERTIBLE TOP
ADJUSTMENTS
ADJUSTMENT
Reasons to adjust the folding top assembly
(1) Pull-down and latching efforts are too high.
(2) Wrinkles appear in the canopy.
(3) Header “slap” when the folding top is raised,
prior to pull down.
(4) Dowel pin alignment.
NOTE: No adjustments should be done at the inter-
nal folding top adjustment screws on the Main Pivot
Bracket of the folding top (these screws are only
for initial settings at the supplier).
Adjustment of the floating bow tension strap
barrels (to add or relieve tension to the canopy).
(1) The folding top should be in a raised position
and latched at the header.
(2) The tension straps are located in the most rear-
ward point of the trunk compartment (Fig. 1).
(3) From inside the trunk area (1 per side) adjust
the tension barrels clockwise to tighten the canopy
and counter clockwise to reduce canopy tension. The
left tension barrel bolt has access. The right tension
bolt must be accessed through the jack storage door
opening.
(4) The 10 mm hex screw located on the bottom
side of each barrel adjusts the tension barrels. Turn
the screw counter clockwise to loosen the canopy.
Turn the screw clockwise to tighten the canopy. Each
screw turn represents 1.25 mm (0.05 in) of adjust-
ment.
(5) It is recommended that the barrels be adjusted
no more than 2.5 mm (0.10 in.).
Fig. 1 TENSION STRAP BARREL LOCATION
1 - TENSION STRAP BARREL
2 - RUBBER PLUG
PT
CONVERTIBLE TOP
23 - 13
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