DODGE NEON 1999 Service Repair Manual

(3) Loosely install bolts holding hinge to lower
A±pillar.
(4) Loosely install bolts holding hinge to door end
frame.
(5) Align hinge to marks made previously and
tighten all bolts.
(6) Install bolts holding door check strap to lower
A±pillar, if removed previously.
(7) Verify door fit and operation. Adjust door hinge
for proper door alignment, if necessary.
DOOR LOCK CYLINDER
REMOVAL
(1) Remove door trim panel and water shield.
(2) Close door glass.
(3) Disconnect door lock rod from latch.
(4) Remove clip holding lock cylinder to door han-
dle.
(5) Pull lock cylinder from door handle (Fig. 13).
INSTALLATION
(1) Push lock cylinder into door handle.
(2) Install clip holding lock cylinder to door han-
dle.
(3) Connect door lock rod from latch.
(4) Install door trim panel and water shield.
DOOR OPENING TRIM WELT
REMOVAL
(1) Open door to gain access to trim welt.
(2) Remove door sill trim panel.
(3) Pull trim welt from door opening flange (Fig.
14).
INSTALLATION
(1) Locate paint dot on backside of trim welt.
(2) Position trim welt to vehicle with paint dot in
the appropriate position.(3) Press trim welt onto door opening flange start-
ing at the paint dot position.
(4) Install door sill trim panel
DOOR SILL TRIM
REMOVAL
(1) Open door to gain access to sill trim.
(2) Disengage clips holding sill trim to door sill
and door opening flange.
(3) Separate door sill trim from vehicle (Fig. 15).
INSTALLATION
(1) Position door sill trim on door sill.
(2) Align locating pins on backside of trim panel to
holes in door sill.
(3) Engage clips on trim panel into slots in door
sill.
(4) Engage clips on trim panel onto door opening
flange.
(5) Press downward on trim panel to fully engage
all clips.
Fig. 13 Door Lock Cylinder
Fig. 14 Door Opening Trim Welt
Fig. 15 Door Sill Trim
23 - 10 BODYPL
REMOVAL AND INSTALLATION (Continued)

FLOOR CONSOLE
REMOVAL
(1) Fully apply parking brake.
(2) Remove screw cover plugs over screws just
rearward of cupholders.
(3) Remove screws holding console to floor bracket
just rearward of cupholders (Fig. 16).
(4) Open console storage compartment lid, if so
equipped.
(5) Remove screw cover plugs over screws near
rear of console, if vehicle is equipped with a non±ar-
mrest console.
(6) Remove screws holding console to floor bracket.
(7) Snap out side attachment covers, if equipped
(Fig. 16).
(8) Remove side attachment bolts holding rear of
console to floor bracket, if equipped.
(9) Remove shift lever knob, if vehicle is equipped
with a manual transmission.
(10) Lift console upward over gear selector and
park brake handle.
(11) Separate console from vehicle.
INSTALLATION
(1) Move floor console into position in vehicle.
(2) Install screws holding console to floor brackets.
(3) Install screw cover plugs.
(4) Install side attachment covers, if equipped.
(5) Install shift lever knob, if vehicle is equipped
with a manual transmission.
(6) Release parking brake and close console stor-
age compartment lid, if so equipped.
FLOOR CONSOLE LATCH
REMOVAL
(1) Lift the floor console lid.
(2) Remove screws attaching the latch to the lid
(Fig. 17).
(3) Remove latch.
INSTALLATION
(1) Place latch in position.
(2) Install screws attaching the latch to the lid.
(3) Ensure the operation of the latch.
(4) Tighten screws to 1.7 N²m (15 in. lbs.) torque.
FRONT DOOR CHECK STOP
REMOVAL
(1) Remove door trim panel and water shield.
(2) Remove bolt holding check stop to hinge pillar.
(3) Remove door speaker.
(4) Remove bolts holding check stop to door end
frame (Fig. 18).
(5) Separate check stop from vehicle.
Fig. 16 Floor Console
Fig. 17 Floor Console Latch
Fig. 18 Front Door Check Stop
PLBODY 23 - 11
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Position door check on vehicle and install bolts
attaching stop to door end frame.
(2) Install door speaker, if so equipped.
(3) Install bolt holding door check stop to hinge
pillar.
(4) Install door trim panel and water shield.
FRONT DOOR GLASSÐ2 DOOR
REMOVAL
(1) Remove door trim panel and water shield.
(2) Remove inner and outer door belt weather-
strips.
(3) Loosen inner belt stabilizer.
(4) Lower door glass to bottom of travel to access
glass attachment bolts.
(5) Remove bolts holding regulator lift channel to
door glass (Fig. 20).
(6) Remove bolts holding rear guide plate to door
glass (Fig. 19).
(7) Separate rear guide plate from door glass.
(8) Lift door glass upward and out of opening at
top of door (Fig. 21).
(9) Remove front guide plate from door glass.
INSTALLATION
(1) Install front guide plate to door glass.
(2) Carefully lower door glass through opening in
top of door.
(3) Position rear guide plate onto door glass and
install bolts.(4) Install nuts holding regulator lift channel to
door glass.
(5) Tighten all door glass fasteners.
(6) Tighten window inner belt stabilizer.
(7) Install inner and outer door belt weatherstrips.
(8) Install door trim panel and water shield.
Fig. 19 Guide Bolts
Fig. 20 Regulator Lift Channel
Fig. 21 Door Glass
23 - 12 BODYPL
REMOVAL AND INSTALLATION (Continued)

FRONT DOOR GLASSÐ4 DOOR
REMOVAL
(1) Remove door trim panel and water shield.
(2) Remove inner door belt weatherstrip.
(3) Loosen window inner belt stabilizer.
(4) Lower door glass to bottom of door to gain
access to attaching bolts.
(5) Remove bolts holding door glass to window reg-
ulator lift plates (Fig. 22).
(6) Disengage door glass from regulator.
(7) Lift door glass upward out of the opening at
the top of door.
INSTALLATION
(1) Carefully lower door glass through opening in
top of door.
(2) Position door glass into window regulator lift
plates.
(3) Install bolts securing door glass to lift plates.
(4) Tighten window inner belt stabilizer.
(5) Install inner door belt weatherstrip.
(6) Install door trim panel and water shield.
FRONT DOOR INNER BELT WEATHERSTRIP
REMOVAL
(1) Remove door trim panel.
(2) Separate weatherstrip from door.
INSTALLATION
(1) Push down on weatherstrip to engage channel
to door panel.
(2) Install door trim panel.
FRONT DOOR LATCH
REMOVAL
(1) Remove door trim panel and water shield.
(2) Close door glass.(3) Disconnect lock and latch rods from door latch
(Fig. 24).
(4) Disengage wire connector from power door lock
motor, if equipped.
(5) Remove screws holding latch to door end
frame.
(6) Separate door latch from vehicle.
INSTALLATION
CAUTION: Do not close door before adjusting the
door latch. Door may fail to re-open.
(1) Position door latch inside door and install
screws holding latch to door end frame.
(2) Engage wire connector into power door lock
motor, if so equipped.
(3) Connect latch and lock rods to door latch.
(4) Install door trim panel and water shield.
(5) Adjust door latch using procedure in this sec-
tion.
Fig. 22 Front Door Glass
Fig. 23 Front Door Inner Belt Weatherstrip
Fig. 24 Front Door Latch
PLBODY 23 - 13
REMOVAL AND INSTALLATION (Continued)

FRONT DOOR LATCH STRIKER
REMOVAL
(1) Mark outline of door latch striker on B-pillar to
aid installation.
(2) Remove screws holding door latch striker to
B-pillar (Fig. 25).
(3) Separate door latch striker from vehicle.
INSTALLATION
Reverse the preceding operation.
FRONT DOOR OUTER BELT WEATHERSTRIP
REMOVAL
(1) Open door glass.
(2) Pull upward at rear end of outer belt weather-
strip.
(3) Separate outer belt weatherstrip from vehicle
(Fig. 26).
INSTALLATION
(1) Starting at leading edge of door, press weather-
strip onto door.(2) Operate window and check for interference
FRONT DOOR OUTSIDE HANDLE
REMOVAL
(1) Remove door trim panel and water shield.
(2) Close door glass.
(3) Disconnect lock and latch rods from door latch.
(4) Remove nut holding door handle retainer to
outer door panel (Fig. 27).
(5) Separate retainer from back of door handle.
(6) Separate door handle from vehicle.
INSTALLATION
(1) Position door handle into door and install
retainer at back of handle.
(2) Install nut holding door handle retainer to
outer door panel.
(3) Connect lock and latch rods to door latch.
(4) Install door trim panel and water shield.
FRONT DOOR TRIM PANEL
REMOVAL
(1) Lower door glass.
(2) Remove screw attaching pull cup to door trim
panel. Two door vehicle, refer to (Fig. 28). Four door
vehicle, refer to (Fig. 29).
(3) Pull inside latch release handle to access
attaching screw and remove. Two door vehicle, refer
to (Fig. 30). Four door vehicle, refer to (Fig. 31).
(4) Remove window regulator crank, if equipped
(Fig. 32).
CAUTION: Pulling on trim panel to disengage fas-
teners will damage the trim panel.
NOTE: Use a fork-type push-in fastener removal
tool.
Fig. 25 Front Door Latch Striker
Fig. 26 Outer Belt WeatherstripÐTypical
Fig. 27 Front Door Outside Handle
23 - 14 BODYPL
REMOVAL AND INSTALLATION (Continued)

(5) Disengage all hidden push-in fasteners attach-
ing trim panel to door (Fig. 33). Ensure that each
push-in fastener is disengaged using the removal
tool.
(6) Tilt trim panel outward to clear locator pins on
backside of trim panel.
(7) Lift trim panel to disengage from retainer
channel on inner belt weatherstrip at the top of the
door.
(8) Disengage clip holding door latch linkage to
back of inside door handle.
(9) Separate latch rod from handle.
CAUTION: Do not allow door trim panel to hang by
the wire connector or wiring.
(10) Disengage wire connector from power door
lock switch, mirror switch, and power window switch,
if equipped.
(11) Separate trim panel from vehicle.
Fig. 28 Front Two Door Pull Cup
Fig. 29 Front Four Door Pull Cup
Fig. 30 Inside Two Door Handle Screw
Fig. 31 Inside Four Door Handle Screw
Fig. 32 Window Crank
PLBODY 23 - 15
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Replace any damaged or missing push±in fas-
teners with original equipment push-in fasteners.
(2) Place trim panel near door.
(3) Engage wire connectors to power lock switch,
mirror switch, and power window switch, if equipped.
(4) Insert latch rod into inside latch release.
(5) Engage clip holding door latch linkage to back
of inside door handle.
(6) Engage trim panel into retainer channel at top
of door and push down to seat.
(7) Locate door trim panel to inner door panel by
aligning locating pins on backside of trim panel to
mating holes in inner door panel. Gently shift panel
forward or rearward if necessary.
(8) Engage hidden push±in fasteners holding trim
panel to door from around perimeter of trim panel.
(9) With the window in the down position, orien-
tate the window regulator crank handle appropri-
ately. Install the right handle at the 10 o'clock
position and the left handle at the 2 o'clock position,
if equipped.
(10) Install screw holding trim panel to door from
behind inside latch release handle.
(11) Install screw inside pull cup holding door trim
panel to bracket.
FRONT DOOR WATER SHIELD
REMOVAL
(1) Remove door trim panel.
(2) Remove Door speaker, if equipped.
(3) Remove door trim pull cup mount bracket.
(4) Disengage clip holding lock linkage to lock but-
ton bell crank.
(5) Peel water shield away from adhesive around
perimeter of inner door panel (Fig. 34).
INSTALLATION
(1) Insure that enough adhesive remains to
securely retain the watershield. Replace as necessary.
(2) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(3) Engage clip holding lock linkage to lock button
bell-crank.
(4) Install door trim pull cup mount bracket.
(5) Install door speaker, if equipped.
(6) Install door trim panel.
FRONT DOOR WEATHERSTRIP
REMOVAL
(1) Using a fork-type prying tool, disengage
push-in fasteners holding weatherstrip to door (Fig.
35).
(2) Separate weatherstrip from door.
INSTALLATION
Reverse the preceding operation.
Fig. 33 Door Trim Panel
Fig. 34 Water Shield
Fig. 35 Front Door Weatherstrip
23 - 16 BODYPL
REMOVAL AND INSTALLATION (Continued)

FRONT OUTBOARD SEAT BELT
REMOVAL
(1) Slide lower seat belt anchor cover upward to
expose bolt.
(2) Remove bolt holding lower anchor bolt to floor
below door sill (Fig. 36).
(3) Separate lower anchor from floor.
(4) Remove rear seat cushion and back.
(5) Remove quarter trim panel.
(6) Guide seat belt webbing through slot in quarter
trim panel.
(7) Disengage wire connector from seat belt retrac-
tor.
(8) Remove bolts holding seat belt retractor to
B-pillar (Fig. 37).
(9) Separate seat belt retractor from vehicle.
INSTALLATION
Reverse the preceding operation. Tighten seat belt
anchor bolt to 39 N´m (29 ft. lbs.).
FRONT SEAT
REMOVAL
(1) Move seat to forward position.
(2) Remove bolts holding rear of seat track to floor.
(3) Move seat to rearward position.
(4) Remove bolts holding front of seat track to floor
crossmember (Fig. 38).
(5) Separate seat from vehicle.
INSTALLATION
(1) Move seat to full rearward position andverify
that both seat tracks are locked into position.
(2) Move seat into position in vehicle. Do not use
the head restraint, side shield, recliner handle, or the
adjuster lift bar to move the seat.
(3) Ensure that the locating tabs on the front
mounting feet are installed through the slits in the
carpet and into the openings in the floor pan cross-
member.
(4) Install and tighten front inboard bolt holding
seat track to floor crossmember.
(5) Install and tighten front outboard bolt holding
seat track to floor crossmember.
(6) Move seat to forward position. Verify that the
inboard and outboard tracks are latched in the full
forward position.
(7) Install and tighten bolts holding rear of seat
track to floor.
Fig. 36 Front Outboard Seat Belt Anchor
Fig. 37 Front Outboard Seat Belt Retractor
Fig. 38 Front Seat
PLBODY 23 - 17
REMOVAL AND INSTALLATION (Continued)

NOTE: The tightening specification for all front seat
retaining bolts is 55 N´m (40 ft. lbs.) torque.
FRONT SEAT BELT BUCKLE
REMOVAL
(1) Move front seat to the forward position.
(2) Remove bolt holding seat belt buckle to seat.
(3) Separate seat belt buckle from seat.
INSTALLATION
Reverse the preceding operation.
FRONT SEAT BELT RETRACTOR
REMOVAL
(1) Remove B-pillar trim.
(2) Remove bolt holding seat belt retractor to
B-pillar (Fig. 39).
(3) Separate seat belt retractor from vehicle.
INSTALLATION
Reverse the preceding operation.
FRONT SHOULDER BELT ADJUSTER
REMOVAL
(1) Remove B-pillar trim.(2) Remove bolt holding shoulder belt adjuster to
B-pillar (Fig. 40).
(3) Separate shoulder belt adjuster from vehicle.
INSTALLATION
Reverse the preceding operation.
FRONT VERTICAL GUIDE BAR
REMOVAL
(1) Remove door trim panel and water shield.
(2) Remove door speaker, if equipped.
(3) Remove front lift guide.
(4) Remove bolt holding top of front guide bar to
inner door panel.
(5) Using a Snap-ontflare-nut socket (FRXM10)
and a hex wrench, remove nut holding bottom of
guide bar to door panel while holding jack screws.
(Fig. 41)
Fig. 39 Front Seat Belt Retractor
Fig. 40 Front Shoulder Belt Adjuster
Fig. 41 Front Vertical Guide Bar
23 - 18 BODYPL
REMOVAL AND INSTALLATION (Continued)

(6) Remove front vertical guide bar through
speaker hole in inner door panel (Fig. 42).
INSTALLATION
Reverse the preceding operation. Verify door glass
alignment, adjust if necessary.
GRILLE
REMOVAL
(1) Release hood latch, open and support hood on
prop rod.
(2) Remove screws holding grille to parking lamps
(Fig. 43).
(3) Remove screw holding grille to radiator closure
panel.
(4) Separate grille from vehicle.
INSTALLATION
(1) Place grille into position on vehicle.
(2) Install screw holding grille to radiator closure
panel.
(3) Install screws holding grille to parking lamps.
HEADLINING
REMOVAL
(1) Remove screws holding sun visors to roof
header panel.
(2) Disengage wire connector from lighted vanity
mirror, if so equipped.
(3) Separate sun visors from vehicle.
(4) Remove A-pillar trim covers.
(5) Remove B-pillar trim panels, if vehicle is a 4
door.
(6) Remove (upper) quarter panel trim panels.
(7) Remove assist handles, if so equipped.
(8) Remove sun visor hooks.
(9) Remove coat hooks, if vehicle is a 4 door.
(10) If vehicle is equipped with a sunroof;
(a) Open sunroof.
(b) Remove trim welt around sunroof opening
(Fig. 44).
(c) Remove sunroof switch pod.
(d) Disconnect sunroof switch pod wire connec-
tors.
(e) Remove screw holding switch pod retainer to
roof.
(11) Remove push±in fastener at rear of headlin-
ing.
(12) Disengage dome lamp wire connector, at rear
of headlining.
(13) Remove push±in fastener holding wiring to
C±pillar.
Fig. 42 Front Guide
Fig. 43 Grille
PLBODY 23 - 19
REMOVAL AND INSTALLATION (Continued)