Chrysler PT Cruiser. Manual — part 907
FRONT WHEELHOUSE
SPLASH SHIELDS
REMOVAL
(1) Hoist and support vehicle on safety stands.
(2) Remove front wheel.
(3) Remove push-in fasteners attaching splash
shield to frame rail forward of suspension (Fig. 7).
(4) Remove push in fasteners attaching splash
shield to frame rail rearward of suspension.
(5) Remove screws attaching wheelhouse splash
shield to front fender.
(6) Remove splash shield from vehicle.
INSTALLATION
(1) Place splash shield in position on vehicle (Fig.
7).
(2) Install screws attaching wheelhouse splash
shield to front fender.
(3) Install push in fasteners attaching splash
shield to frame rail rearward of suspension.
(4) Install push in fasteners attaching splash
shield to frame rail forward of suspension.
(5) Install front wheel.
(6) Lower vehicle.
FUEL FILL DOOR
REMOVAL
(1) Open the fuel filler door.
(2) Remove the screws attaching the door to the
quarter panel (Fig. 8).
(3) Remove the door from the panel.
INSTALLATION
(1) Position the fuel filler door on the quarter
panel with the screw holes aligned (Fig. 8).
(2) Install the screws attaching the fuel filler door
to the quarter panel.
GRILLE
REMOVAL
(1) Open hood and support hood on prop rod.
(2) Remove screws attaching grille to fender and
radiator closure panel (Fig. 9).
(3) Pull top of grille up and outward to disengage
hooks from fender.
(4) Remove grille from vehicle.
(5) Remove chrome strips, if necessary. Using a
small flat blade tool to release chrome strips tabs
(Fig. 10).
Fig. 7 FRONT WHEELHOUSE SPLASH SHIELD
1 - FRONT FENDER
2 - FRONT FENDER SPLASH SHIELD
Fig. 8 FUEL FILLER DOOR
1 - FUEL FILLER DOOR
23 - 86
EXTERIOR
PT
INSTALLATION
(1) Install the chrome strips to grille (7), if
equipped (Fig. 11). Place chrome strip into position,
and press on chrome strip until it is locked into posi-
tion.
(2) Place grille into position on vehicle, engage
lower hook into fascia first, then set top of grille on
to the radiator closure panel (Fig. 12).
(3) Install screw (4) attaching grille to radiator clo-
sure panel.
(4) Close hood.
Fig. 9 GRILLE
1 - GRILLE
2 - RETAINER
Fig. 10 GRILLE - WITH CHROME STRIPS
1 - SCREWS (4) ATTACHING GRILLE TO FENDER AND
RADIATOR CLOSURE PANEL
2 - SPRING NUT (4)
3 - LOWER RADIATOR GRILLE AND FASCIA
4 - RADIATOR GRILLE
5 - CHROME STRIPS (7)
Fig. 11 GRILLE - WITH CHROME STRIPS
1 - SCREWS (4) ATTACHING GRILLE TO FENDER AND
RADIATOR CLOSURE PANEL
2 - SPRING NUT (4)
3 - LOWER RADIATOR GRILLE AND FASCIA
4 - RADIATOR GRILLE
5 - CHROME STRIPS (7)
Fig. 12 GRILLE
1 - GRILLE
2 - RETAINER
PT
EXTERIOR
23 - 87
GRILLE (Continued)
HEADER MOLDING - PT-27
REMOVAL - PT-27 ONLY
(1) Lower top.
(2) Disengage
clips
attaching
header
molding
panel to upper windshield surround frame (Fig. 13).
(3) Remove header molding from vehicle.
INSTALLATION - PT-27 ONLY
NOTE: Use a brand new header molding or replace
the clips as needed on the header molding.
(1) Place header molding into position (Fig. 13).
(2) Align clips to mating holes in the windshield
surround frame.
(3) Push clips on header molding into the seated
position.
LUGGAGE RACK CROSSBAR
REMOVAL
(1) Loosen the end cap set screws on both side
rails and remove end caps. (Fig. 14)
(2) Release the cross bars and slide off the side
rails.
INSTALLATION
(1) Install the crossbars onto the side rails.
(2) Install the end caps and tighten the set screws.
(3) Place the cross bars into the far rear position
and lock down.
LUGGAGE RACK SIDE RAIL
REMOVAL
(1) Remove the crossbars. (Refer to 23 - BODY/EX-
TERIOR/LUGGAGE
RACK
CROSSBAR
-
REMOVAL)
(2) Disconnect and isolate the battery negative
cable.
NOTE: Remove the following trim panels from the
same side as the side rail only.
(3) Remove the a-pillar trim. (Refer to 23 - BODY/
INTERIOR/A-PILLAR TRIM - REMOVAL)
(4) Remove the sunvisor and holder. (Refer to 23 -
BODY/INTERIOR/SUN VISOR - REMOVAL)
(5) Partially remove the sunroof trim lace. (Refer
to 23 - BODY/SUNROOF/OPENING TRIM LACE -
REMOVAL)
(6) Remove the upper b-pillar trim. (Refer to 23 -
BODY/INTERIOR/B-PILLAR TRIM - REMOVAL)
(7) Remove the front and rear assist handles.
(8) Remove the upper c-pillar trim. (Refer to 23 -
BODY/INTERIOR/C-PILLAR TRIM - REMOVAL)
(9) Remove the upper d-pillar trim. (Refer to 23 -
BODY/INTERIOR/D-PILLAR TRIM - REMOVAL)
(10) Remove push pin fastener at the rear of the
head liner.
(11) Lower headliner to gain access to the side rail
nuts.
(12) Remove the five side rail nuts and remove the
side rail.
Fig. 13 HEADER MOLDING
1 - HEADER MOLDING
2 - WINDSHIELD OPENING FRAME
Fig. 14 LUGGAGE RACK
1 - SIDE RAILS
2 - CROSSBARS
3 - END CAPS
4 - NUTS (5 PER SIDE)
23 - 88
EXTERIOR
PT
INSTALLATION
(1) Install the side rail and side rail bolts.
(2) Apply a suitable body sealer to the bolt threads
and install the nuts.
(3) Raise the headliner and install the push pin
fastener at the rear.
(4) Install the upper d-pillar trim. (Refer to 23 -
BODY/INTERIOR/D-PILLAR TRIM - INSTALLA-
TION)
(5) Install the upper c-pillar trim. (Refer to 23 -
BODY/INTERIOR/C-PILLAR
TRIM
-
INSTALLA-
TION)
(6) Install the assist handles.
(7) Install the upper b-pillar trim. (Refer to 23 -
BODY/INTERIOR/B-PILLAR
TRIM
-
INSTALLA-
TION)
(8) Install the sunroof trim lace. (Refer to 23 -
BODY/SUNROOF/OPENING TRIM LACE - INSTAL-
LATION)
(9) Install the sunvisor. (Refer to 23 - BODY/INTE-
RIOR/SUN VISOR - INSTALLATION)
(10) Install the a-pillar trim. (Refer to 23 - BODY/
INTERIOR/A-PILLAR TRIM - INSTALLATION)
(11) Reconnect the battery.
(12) Install the crossbars. (Refer to 23 - BODY/EX-
TERIOR/LUGGAGE RACK CROSSBAR - INSTAL-
LATION)
RADIATOR CLOSURE PANEL
REMOVAL
(1) Open hood.
(2) Mark bolt locations on the upper radiator clo-
sure panel (Fig. 15).
(3) Remove fasteners attaching radiator closure
panel to fenders.
(4) Move temperature sensor as necessary.
(5) Remove bolt attaching lower radiator closure
panel to the upper radiator closure panel.
(6) For replacement of upper radiator closure
panel, remove hood latch, and any other hardware.
INSTALLATION
(1) Place in position the upper radiator closure
panel (Fig. 15).
(2) Install bolts attaching upper radiator closure
panel to fenders. Check bolt alignment marks.
(3) Install bolt attaching the lower radiator closure
panel to upper radiator closure panel.
(4) Place in position temperature sensor in posi-
tion.
(5) Install hood latch and cable.
(6) Check hood latch operation.
SIDE VIEW MIRROR
REMOVAL
REMOVAL
(1) Disengage the clips retaining the side mirror
bezel to stanchion. (Left side only with manual mir-
ror).
(2) Remove door trim panel if necessary.
(3) Remove nuts attaching mirror to door inner
panel (Fig. 16)or (Fig. 17).
(4) Manual mirrors snap left side manual remote
from bezel.
(5) Electrical mirrors disconnect wire connector.
(6) Remove mirror from vehicle.
Fig. 15 RADIATOR CLOSURE PANEL
1 - UPPER RADIATOR CLOSURE PANEL
2 - UPPER CLOSURE ATTACHING FASTENERS
3 - TEMPERATURE SENSOR
4 - FASTENER ATTACHING LOWER CLOSURE PANEL TO
UPPER CLOSURE PANEL
PT
EXTERIOR
23 - 89
LUGGAGE RACK SIDE RAIL (Continued)
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