Chrysler PT Cruiser. Manual — part 941
INSTALLATION - PT-27 ONLY
CAUTION: Open the left front door glass before
installing windshield to avoid pressurizing the pas-
senger compartment. If a door is slammed before
urethane bonding is cured, water leaks can result.
Allow the urethane at least 24 hours to cure before
returning the vehicle to use.
To avoid stressing the replacement windshield, the
urethane bonding material on the windshield fence
should be smooth and consistent to the shape of
the replacement windshield. The support spacers
should be cleaned and properly installed on weld
studs or repair screws at bottom of windshield
opening.
Fig. 11 WINDSHIELD LOADING
1 - ENCAPSULATION LOCATOR PIN
2 - ENCAPSULATION HOOK
Fig. 12 URETHANE APPLICATION
1 - WINDSHIELD ASSEMBLY WITH ENCAPSULATION
2 - GLASS PRIMERS
3 - WINDSHIELD OPENING PRIMER
4 - URETHANE
23 - 222
STATIONARY GLASS
PT
WINDSHIELD (Continued)
(1) Verify support spacers in windshield opening. If
not present, install spacers as indicated. (Fig. 14)
(2) Position windshield into opening by contacting
header spacers then loading the glass hooks onto the
panel hooks. (Fig. 15)
(3) Verify glass encapsulation lays evenly along
roof panel and that there is no gapping of the glass
to spacers in the windshield opening. If gaps are
present, the pinch weld fence must be formed to the
shape of the new glass.
(4) Remove replacement windshield from opening.
(5) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart. (Fig. 16)
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER
TO
CLEAN
WINDSHIELD
BEFORE
APPLYING
GLASS
PREP AND
PRIMER.
POOR
ADHESION CAN RESULT.
(6) Clean inside of windshield with ammonia based
glass cleaner and lint-free cloth.
(7) Apply Glass Prep adhesion promoter 25 mm (1
in.) wide around perimeter of windshield and wipe
with clean/dry lint-free cloth until no streaks are vis-
ible (Fig. 13).
(8) Apply Glass Primer 25 mm (1 in.) wide around
perimeter of windshield. Allow at least three minutes
drying time.
(9) Apply a bead of urethane on windshield glass
as indicated. (Fig. 16)
(10) With the aid of a helper, position the wind-
shield over the windshield opening and install con-
tacting header spacers then load glass hooks onto the
roof panel hooks.
(11) Push windshield into opening until there is
glass to spacers in the windshield opening
(12) Clean excess urethane from exterior with
Mopar, Super clean or equivalent.
(13) Apply
tape
to
windshield
assembly
as
required if gap exists around windshield opening.
(14) After urethane has cured, remove tape strips
and water test windshield to verify repair.
(15) Install cowl covers, A-pillar trim and header
trim molding.
(16) Install inside rear view mirror.
(17) Allow urethane to cured for 10 to 12 hours.
Remove tape strips and water test windshield.
Fig. 13 WINDSHIELD INSTALLATION
1- WINDSHIELD ASSEMBLY WITH ENCAPSULATION
2 - ENCAPSULATION SQUEAK REDUCTION TAPE
3 - ANTI-SQUEAK LUBRICANT
Fig. 14 WINDSHIELD SUPPORTS
1 - SUPPORT SPACERS ON ROOF PANEL (9mm X 20mm X
3mm)
2 - SUPPORT SPACERS ON COWL PANEL (9mm X 20mm X
6mm)
3 - ROOF PANEL HOOK
4 - ROOF PANEL SQUEAK REDUCTION TAPE
PT
STATIONARY GLASS
23 - 223
WINDSHIELD (Continued)
Fig. 15 WINDSHIELD LOADING
1 - ENCAPSULATION LOCATOR PIN
2 - ENCAPSULATION HOOK
Fig. 16 URETHANE APPLICATION
1 - WINDSHIELD ASSEMBLY WITH ENCAPSULATION
2 - GLASS PRIMERS
3 - WINDSHIELD OPENING PRIMER
4 - URETHANE
23 - 224
STATIONARY GLASS
PT
WINDSHIELD (Continued)
SUNROOF
TABLE OF CONTENTS
page
page
SUNROOF
. . . . . . . . . . . . . . . . . . . . . . . . 225
DIAGNOSIS AND TESTING - SUNROOF
SUNROOF MODULE ASSEMBLY - VEHICLES
BUILT BEFORE 9/23/02
REMOVAL- VEHICLES BUILT BEFORE 9/23/02
INSTALLATION- VEHICLES BUILT BEFORE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
ELECTRONIC CONTROL MODULE - VEHICLE
BUILT BEFORE 9/10/02
REMOVAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
. . . . . . . . . . . . . . . . . . . . . . . . 228
SUNROOF DRIVE MOTOR
. . . . . . . . . . . . . . . . . . . . . . . . . . 229
REMOVAL - VEHICLES BUILT ON 9/23/02
AND LATER . . . . . . . . . . . . . . . . . . . . . . . . . 229
. . . . . . . . . . . . . . . . . . . . . . 230
INSTALLATION - VEHICLES BUILT ON
9/23/02 AND LATER . . . . . . . . . . . . . . . . . . . 230
SUNROOF CONTROL SWITCH
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
. . . . . . . . . . . . . . . . . . . . . . . . 230
WIND DEFLECTOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
. . . . . . . . . . . . . . . . . . . . . . . . 230
GLASS PANEL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
. . . . . . . . . . . . . . . . . . . . . . . . 231
SUNROOF GLASS PANEL ADJUSTMENT
SUNROOF SUNSHADE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
. . . . . . . . . . . . . . . . . . . . . . . . 232
SUNROOF GLASS PANEL SEAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
. . . . . . . . . . . . . . . . . . . . . . . . 232
OPENING TRIM LACE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
. . . . . . . . . . . . . . . . . . . . . . . . 232
SUNROOF TROUGH GUIDE ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
. . . . . . . . . . . . . . . . . . . . . . . . 233
DRAIN TUBE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
. . . . . . . . . . . . . . . . . . . . . . . . 233
SUNROOF
DESCRIPTION
WARNING: Keep fingers and other body parts out
of sunroof opening at all times.
The sunroof features a power sliding glass panel
and a sunshade which can be manually positioned
anywhere along its travel, rearward of glass panel
front edge.
The sunroof is electrically operated from two
switches located on the windshield header, rearward
of the map lamp. To operate the sunroof the ignition
switch must be in either the Accessory or On/Run
position. One switch (vent) is a push button type and
opens the sunroof to the vent position only. The other
switch (open/close) is a rocker type for opening and
closing the sunroof. Pressing and releasing the open
button once the sunroof will express open and the
wind deflector will rise. If the button is pressed a
second time the sunroof will stop in that position.
Pressing and holding the close button will close the
sunroof. If the close button is released the sunroof
will stop in that position.
DIAGNOSIS AND TESTING - SUNROOF
Before beginning sunroof diagnostics verify that all
other power accessories are in proper operating con-
dition. Refer to Sunroof Diagnostic Chart for possible
causes. If not, a common electrical problem may
exist. Refer to Wiring Diagrams, in this publication
for circuit, splice and component descriptions. Check
the condition of the circuit protection (20 amp circuit
breaker in cavity 19 of the Junction Block). Inspect
all wiring connector pins for proper engagement and
continuity. Check for battery voltage at the power
sunroof controller, refer to Wiring Diagrams, for cir-
cuit information. If battery voltage of more than 10
volts is detected at the controller, proceed with the
following tests (the controller will not operate at less
than 10 volts).
Before beginning diagnosis for wind noise or water
leaks, verify that the problem was not caused by
releasing the control switch before the sunroof was
fully closed. The sunroof module has a water-man-
agement system. If however, the sunroof glass is in a
partial closed position, high pressure water may be
forced beyond the water management system bound-
aries and onto the headlining.
PT
SUNROOF
23 - 225
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