Chrysler PT Cruiser. Manual — part 904
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DOORS - REAR
TABLE OF CONTENTS
page
page
REAR DOOR APPLIQUE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
. . . . . . . . . . . . . . . . . . . . . . . . . 75
REAR DOOR CHECK STRAP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
. . . . . . . . . . . . . . . . . . . . . . . . . 75
REAR DOOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
. . . . . . . . . . . . . . . . . . . . . . . . . 76
REAR DOOR GLASS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
. . . . . . . . . . . . . . . . . . . . . . . . . 76
REAR DOOR OUTSIDE HANDLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
. . . . . . . . . . . . . . . . . . . . . . . . . 77
REAR DOOR HINGE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
. . . . . . . . . . . . . . . . . . . . . . . . . 77
REAR DOOR LATCH
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
. . . . . . . . . . . . . . . . . . . . . . . . . 78
REAR DOOR LATCH STRIKER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
. . . . . . . . . . . . . . . . . . . . . . . . . 79
REAR DOOR TRIM PANEL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
. . . . . . . . . . . . . . . . . . . . . . . . . 79
REAR DOOR WATER DAM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
. . . . . . . . . . . . . . . . . . . . . . . . . 79
REAR DOOR WINDOW REGULATOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
. . . . . . . . . . . . . . . . . . . . . . . . . 80
REAR DOOR APPLIQUE
REMOVAL
(1) Open rear door.
(2) Lower door window to the lowest position (Fig.
1).
(3) Remove front and rear screws attaching out-
side belt weatherstrip and remove from door (Fig. 2).
(4) Remove glass run weatherstrip as necessary to
access the three screws in the B-pillar applique. The
glass run weatherstrip will need to be free of the
glass on forward edge, so that the front edge of the
glass can push outward to access the lower screw
(Fig. 3).
(5) Place a shop towel between the tract and glass
so that screw(s) do not fall in to the door opening.
(6) Remove screws attaching B-pillar applique.
(7) Remove B-pillar applique from door.
(8) To remove C-pillar applique pull glass run
weatherstrip down as necessary to access the three
screws in the C-pillar applique (Fig. 4).
(9) Remove screws attaching C-pillar applique.
(10) Remove C-pillar from door.
Fig. 1 REAR DOOR APPLIQUE
1 - REAR DOOR C=PILLAR APPLIQUE
2 - REAR DOOR
3 - REAR DOOR B-PILLAR
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DOORS - REAR
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INSTALLATION
(1) Position C-pillar applique on door.
(2) Install attaching screws to C-pillar.
(3) Install C-pillar applique glass run weatherstrip
into position (Fig. 4).
(4) Position B-pillar applique on door.
(5) With shop towel between the tract and glass so
that screw(s) do not fall in to the door opening.
(6) Install attaching screws to B-pillar applique.
(7) Install glass run weatherstrip into position on
the door frame (Fig. 3).
(8) Place outside belt weatherstrip into position.
(9) Install front and rear screws attaching outside
belt weatherstrip (Fig. 2).
(10) Raise door window glass.
(11) Close door.
REAR DOOR CHECK STRAP
REMOVAL
(1) Raise glass to full up position.
(2) Remove door trim panel.
(3) Remove bolts attaching check strap to hinge
pillar (Fig. 5).
(4) Remove check strap seal from door end frame.
(5) Remove bolts attaching check strap to door end
frame.
(6) Remove check strap from vehicle.
INSTALLATION
CAUTION: Do not close door before adjusting the
door latch. Door may fail to open.
(1) Position door check strap on door.
(2) Install check strap attaching bolts to the door
end frame (Fig. 5).
Fig. 2 REAR DOOR OUTSIDE WEATHERSTRIP
1 - REAR DOOR FRAME
2 - REAR DOOR GLASS RUN WEATHERSTRIP
Fig. 3 REMOVE LOWER SCREW
1 - UPPER DOOR FRAME
2 - LOWER SCREW
3 - SHOP TOWEL
4 - DOOR WINDOW GLASS
Fig. 4 DOOR RUN WEATHERSTRIP
1 - UPPER DOOR FRAME
2 - DOOR RUN WEATHERSTRIP
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DOORS - REAR
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REAR DOOR APPLIQUE (Continued)
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(3) Install check strap seal. If seal is damaged or
worn replace seal.
(4) Install check strap attaching bolts to the hinge
pillar.
(5) Install water shield and door trim panel.
REAR DOOR
REMOVAL
(1) Open door and support on a suitable lifting
device.
(2) Disconnect the wire connector at the hinge pil-
lar.
(3) Remove bolts attaching door check strap to
B-pillar.
(4) Mark door hinges for reinstallation.
(5) Remove bolts attaching lower hinge to door
(Fig. 5).
(6) Remove bolts attaching upper hinge to door.
INSTALLATION
(1) Install bolts to the upper hinge to door (Fig. 5).
(2) Install bolts to the lower hinge to door.
(3) Connect the wire connector at the B-pillar.
(4) Remove lifting device.
(5) Install door check strap bolts.
(6) Adjust door as necessary.
REAR DOOR GLASS
REMOVAL
(1) Remove door trim panel and inner belt weath-
erstrip.
(2) Lower the window to 50 mm (2 ins.) from bot-
tom of travel.
(3) Loosen bolts attaching rear lower run channel
to inner door panel (Fig. 6).
(4) Remove rear run channels from door.
(5) Loosen screws attaching window regulator to
glass.
(6) Remove glass.
(7) Lift door glass upward out of the opening at
the top of door.
INSTALLATION
(1) Lower door glass through opening in top of
door and into position in the window regulator (Fig.
6).
(2) Raise window glass and regulator to full up
position.
(3) Tighten screws attaching window regulator to
glass.
(4) Install lower belt brackets.
(5) Install inner door belt door trim panel and
inner belt weatherstrip.
(6) Install outer belt weatherstrip.
(7) Operate window and check for interference.
Adjust glass as necessary.
Fig. 5 REAR DOOR CHECK STRAP
1 - REAR DOOR UPPER HINGE
2 - REAR DOOR
3 - REAR DOOR CHECK STRAP
4 - REAR DOOR LOWER HINGE
Fig. 6 REAR DOOR GLASS
1 - REAR DOOR WINDOW GLASS
2 - REAR DOOR
3 - REAR DOOR WINDOW POWER REGULATOR
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DOORS - REAR
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REAR DOOR CHECK STRAP (Continued)
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REAR DOOR OUTSIDE
HANDLE
REMOVAL
(1) Remove door trim panel.
(2) Raise door glass.
(3) Disengage clips attaching linkage rods to door
latch.
(4) Remove nuts attaching outside handle to door
(Fig. 7).
(5) Remove outside handle.
INSTALLATION
(1) Connect lock and latch rods to door handle.
(2) Position door outside handle in opening (Fig.
7).
(3) Tighten attaching nuts.
(4) Connect linkage rods to latch.
(5) Install door trim panel.
REAR DOOR HINGE
REMOVAL
NOTE: If both hinges on one door are to be
replaced, remove and install one hinge completely
prior to beginning the second hinge.
(1) With rear door closed apply tape to secure door
into body.
(2) Open front door.
(3) Mark position of hinge on both the door end
frame and lower B-pillar to ease installation.
(4) Remove B-pillar lower trim panel.
(5) Remove bolts attaching hinge to door end
frame (Fig. 5).
(6) Remove bolts attaching hinge to lower B-pillar.
(7) Remove door hinge from vehicle.
INSTALLATION
NOTE: If both hinges on one door are to be
replaced, remove and install one hinge completely
prior to beginning the second hinge.
NOTE: Do not grease door hinges.
Fig. 7 REAR DOOR OUTSIDE HANDLE
1 - REAR DOOR BELLCRANK TO LATCH LINK AND SLEEVE
2 - REAR DOOR INSIDE ROD TO LATCH LINK AND SLEEVE
3 - REAR DOOR LOCK LATCH
4 - REAR DOOR
5 - REAR DOOR OUTSIDE HANDLE
6 - REAR DOOR LATCH LINKAGE KNOB AND ROD
7 - REAR DOOR OUTSIDE HANDLE LINK TO LATCH
8 - REAR DOOR WIRE POWER LOCK CONNECTOR
9 - REAR DOOR POWER LOCK MOTOR AND BRACKET
10 - REAR DOOR POWER LOCK ACTUATOR TO LATCH LINK
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DOORS - REAR
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