Chrysler PT Cruiser. Manual — part 900
CONDITION - NON-PARALLEL GAP BETWEEN DOOR AND
QUARTER GLASSES
(1) Verify that the door glass and quarter glass
adjustment procedures have been checked.
(2) Apply masking tape to outside glass surface in
locations (10) (Fig. 22).
(3) Mark tape at the two locations and then drop
top.
(4) With vehicle running, drive quarter glass full
up and then drive door glass up and mark tape at
the two locations (10).
(5) If gap not parallel to within 1.5 mm, loosen
cross car screw (8), cross car screw (7) and cross car
screw (6) and rotate quarter glass regulator with
quarter glass to body and then tighten to 8.5 N·m (75
in. lbs.).
(6) Repeat test using Steps 3 thought 5, if still can
not get parallelism within 1.5 mm then proceed to
Step 7.
(7) Remove quarter glass regulator with glass and
increase slot size, forward 2.0 mm at cross car screw
location (6) only.
(8) Install the quarter glass regulator with glass
and repeat Step 1 thought 5.
Fig. 22 CHECK DISTANT
1 - CROSS CAR SCREW - IN AND OUT ADJUSTMENT
2 - UP STOP SCREWS
3 - CROSS CAR SCREW IN - AND OUT ADJUSTMENT
4 - FORE AND AFT GLASS ADJUSTMENT SCREWS
5 - UP STOP BRACKET - UP AND DOWN ADJUSTMENT
6 - CROSS CAR SCREW - IN AND OUT ADJUSTMENT
7 - CROSS CAR SCREW - IN AND OUT ADJUSTMENT
8 - CROSS CAR SCREW - IN AND OUT ADJUSTMENT
9 - FORE AND AT GLASS ADJUSTMENT SCREWS
10 - CHECK DISTANT
23 - 58
DOOR - FRONT
PT
FRONT DOOR GLASS (Continued)
CONDITION - QUARTER GLASS SEAL FOLD OVER DURING
TRAVEL WITH DOOR GLASS FULL UP AND TOP UP OR
DOWN
(1) Verify that the door glass and quarter glass
adjustment procedures have been checked.
(2) With vehicle running, drive door glass full up
and then cycle quarter glass full up to full down and
repeat several times with the top down.
(3) Check the quarter glass seal for fold over (Fig.
23) and (Fig. 24).
(4) Adjust cross car screw (6) counterclockwise one
rotation.
(5) With vehicle running, cycle quarter glass full
up to full down and repeat several times with the top
down and door glass up. If adjustment is still
required repeat Step 3
(6) With vehicle running, top up and door glass up
and cycle quarter glass full up to full down and
repeat several times. If adjustment is still required
repeat Steps 3 thought 5.
Fig. 23 QUARTER GLASS SEAL FOLD OVER
1 - CROSS CAR SCREW - IN AND OUT ADJUSTMENT
2 - UP STOP SCREWS
3 - CROSS CAR SCREW IN - AND OUT ADJUSTMENT
4 - FORE AND AFT GLASS ADJUSTMENT SCREWS
5 - UP STOP BRACKET - UP AND DOWN ADJUSTMENT
6 - CROSS CAR SCREW - IN AND OUT ADJUSTMENT
7 - CROSS CAR SCREW - IN AND OUT ADJUSTMENT
8 - CROSS CAR SCREW - IN AND OUT ADJUSTMENT
9 - FORE AND AT GLASS ADJUSTMENT SCREWS
10 - QUARTER GLASS SEAL
Fig. 24 MEASURE GAP
1 - DOOR GLASS
2 - GAP
3 - QUARTER GLASS
PT
DOOR - FRONT
23 - 59
FRONT DOOR GLASS (Continued)
CONDITION - INTERMEDIATE REAR OF DOOR GLASS NOT
DRIVING INTO THE TOP SEAL AND/OR NOISE AT REAR
BOTTOM OF THE DOOR
(1) Remove door trim panel.
(2) Inspect bracket assembly clinch/weld nut to
verify not damaged (loose from bracket, allowing
screw to move cross car) at door cross car screw (3)
(Fig. 25).
(3) If bracket assembly is damaged, replace part.
Fig. 25 DOOR GLASS NOT DRIVING INTO THE TOP SEAL
1 - CROSS CAR SCREW - IN AND OUT ADJUSTMENT
2 - UP STOP SCREWS
3 - CROSS CAR SCREW IN - AND OUT ADJUSTMENT
4 - FORE AND AFT GLASS ADJUSTMENT SCREWS
5 - UP STOP BRACKET - UP AND DOWN ADJUSTMENT
6 - CROSS CAR SCREW - IN AND OUT ADJUSTMENT
7 - CROSS CAR SCREW - IN AND OUT ADJUSTMENT
8 - CROSS CAR SCREW - IN AND OUT ADJUSTMENT
9 - FORE AND AT GLASS ADJUSTMENT SCREWS
23 - 60
DOOR - FRONT
PT
FRONT DOOR GLASS (Continued)
FRONT DOOR OUTSIDE
HANDLE
REMOVAL
REMOVAL
(1) Remove door trim panel and water dam.
(2) Move door glass to the up position.
(3) Disconnect outside door handle link to latch.
(4) Remove nut attaching outside door handle to
outer door panel (Fig. 26).
(5) Remove door handle from vehicle.
REMOVAL - PT-27 ONLY
(1) Remove door trim panel and water dam.
(2) Move door glass to the up position.
(3) Disconnect outside door handle link to latch.
(4) Remove nut attaching outside door handle to
outer door panel (Fig. 27).
(5) Remove door handle from vehicle.
Fig. 26 FRONT DOOR OUTSIDE HANDLE
1 - FRONT DOOR
7 - KEY CYLINDER GASKET
2 - FRONT DOOR INSIDE REMOTE HANDLE TO LATCH LINK &
SLEEVE
8 - KEY CYLINDER
3 - FRONT DOOR LOCK KNOB LINK TO LATCH
9 - FRONT DOOR KEY CYLINDER TO LATCH LINK
4 - FRONT DOOR OUTSIDE HANDLE
10 - CENTRAL LOCKING SWITCH
5 - FRONT DOOR OUTSIDE HANDLE TO LATCH LINK
11 - FRONT DOOR OVERRIDE LOCKS LATCH
6 - KEY
12 - FRONT DOOR AJAR SWITCH BUMPER
PT
DOOR - FRONT
23 - 61
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