DODGE NEON 1999 Service Repair Manual

INSTALLATION
(1) Place weather-strip in position on B-pillar
retainer channels.
(2) Insert weather-strip into channels.
(3) Using a suitable awl, zip retaining lip on back
of weather-strip into B-pillar and roof rail channels.
(4) Install push-in fasteners to hold weather-strip
to B-pillar, hinge pillar and quarter panel.
SIDE COWL TRIM
REMOVAL
(1) Disengage clips holding cowl trim to cowl side
panel.
(2) Separate cowl trim from vehicle (Fig. 71).
INSTALLATION
(1) Position cowl trim panel to inner cowl panel.
(2) Align locating pins on backside of cowl trim
panel to mating holes in inner cowl panel.
(3) Push clips on trim panel into slots in inner
cowl panel.
SIDE VIEW MIRROR
REMOVAL
(1) Remove side view mirror cover.
(2) Remove door trim panel.
(3) Remove water shield if equipped with power
mirror.(4) Disengage wire connector from power mirror
motor, if equipped.
(5) Remove bolts holding mirror to stanchion (Fig.
72).
(6) Separate mirror from vehicle.
INSTALLATION
(1) Position side view mirror on vehicle and install
nuts attaching mirror to stanchion.
(2) Engage wire connector from power window
motor, if so equipped.
(3) Install water shield if equipped with power
mirror.
Fig. 72 Side View Mirror
Fig. 71 Side Cowl Trim
23 - 30 BODYPL
REMOVAL AND INSTALLATION (Continued)

(4) Install door trim panel.
(5) Install side view mirror trim cover.
SIDE VIEW MIRROR STANCHION
REMOVAL
(1) Remove side view mirror.
(2) Remove bolt holding top of side view mirror
stanchion to inner door panel.
(3) Remove bolts holding stanchion to outer door
panel (Fig. 73).
(4) Remove nut holding stanchion jack-screw to
inner door panel.
(5) Disengage push-in fastener holding door open-
ing weatherstrip to stanchion.
(6) Separate stanchion from vehicle.
INSTALLATION
Reverse the preceding operation. Using a Snap-on
flare-nut socket (FRXM10) and hex-wrench adjust
the jack-screw at bottom of stanchion to achieve
proper alignment.
SIDE VIEW MIRROR TRIM COVER
REMOVAL
(1) Disengage clips holding side view mirror cover
to stanchion (Fig. 74).
(2) Separate mirror cover from vehicle.
INSTALLATION
Reverse the preceding operation.
SUN VISOR
All vehicles with driver and passenger side airbags
must have a colored coded five Bullet point airbagwarning label applied to the sun visor, verify label
availability and ensure the label is installed.
REMOVAL
(1) Remove sun visor from center support.
(2) Remove screws holding sun visor to roof
header.
(3) Remove sun visor from header.
(4) If equipped, disconnect wire connector from
body harness.
(5) Remove sun visor from vehicle.
INSTALLATION
For installation, reverse the above procedures.
SUN VISOR SUPPORT
REMOVAL
(1) Disengage sun visor from center support.
(2) Remove screw holding support to roof header,
(3) Remove support from vehicle.
INSTALLATION
For installation, reverse the above procedures.
TRUNK CARPET
REMOVAL
(1) Remove push in fasteners holding carpet to
shelf panel. Fasteners are accessed from inside the
vehicle (Fig. 75).
(2) Pull out leading flaps of the carpet through the
opening from the shelf panel.
Fig. 73 Side View Mirror Stanchion
Fig. 74 Side View Mirror Trim Cover
PLBODY 23 - 31
REMOVAL AND INSTALLATION (Continued)

(3) Pull carpet from under the springs.
(4) Remove trunk carpet from vehicle.
INSTALLATION
(1) Place carpet in truck and smooth out.
(2) Tuck both sides of the carpet ends under
springs.
(3) Position the leading flaps of the carpet through
the opening onto the shelf panel.
(4) Install push in fasteners to secure the carpet to
shelf panel (install fasteners from inside the vehicle).
(5) Overlap the slits in the back of the carpet so
the center section lays over the outer sections.
TRUNK LATCH
REMOVAL
(1) Release trunk lid latch and open trunk lid.
(2) Remove bolts holding trunk latch to trunk lid
(Fig. 76).
(3) Separate trunk latch from trunk lid.
(4) Disconnect remote trunk latch release cable
form trunk latch.
(5) Disengage trunk ajar switch connector from
latch.
(6) Separate latch from vehicle.
INSTALLATION
(1) Position latch in vehicle and engage trunk ajar
switch connector to latch.
(2) Connect remote trunk latch release cable to
trunk latch.
(3) Install bolts holding trunk latch to trunk lid.
TRUNK LATCH STRIKER
REMOVAL
(1) Release trunk lid latch and open trunk lid.
(2) Remove push-in fasteners holding trunk lining
to tail panel.(3) Separate trunk lining from tail panel.
(4) Remove bolts holding trunk latch striker to tail
panel (Fig. 77).
(5) Separate striker from vehicle.
INSTALLATION
Reverse the preceding operation.
TRUNK LID
REMOVAL
(1) Release trunk latch and open trunk lid.
(2) Mark bolt locations on inside of trunk lid to aid
installation.
(3) Disengage clips holding wire harness and
trunk lid release cable to trunk lid.
(4) Disengage wire connector and release cable
from trunk latch.
(5) Remove bolts holding top of hinge to trunk lid
(Fig. 78).
(6) With aid from a helper, remove bolts holding
bottom of hinge to trunk lid.
Fig. 75 Trunk Carpet
Fig. 76 Trunk Latch
Fig. 77 Trunk Latch Striker
23 - 32 BODYPL
REMOVAL AND INSTALLATION (Continued)

(7) Separate trunk lid from vehicle.
INSTALLATION
(1) Place trunk lid in position on vehicle.
(2) With aid from a helper, install bolts to hold bot-
tom of hinge to trunk lid.
(3) Install bolts to hold top of hinge to trunk lid.
(4) Align trunk lid to achieve equal spacing on all
sides and flush across gaps.
(5) Verify trunk lid operation and sealing.
(6) Connect wire connector and release cable on
latch.
(7) Install clips to hold wire harness and cable to
trunk lid.
TRUNK LID LIFT SPRINGS
REMOVAL
WARNING: USE EYE AND HAND PROTECTION
WHEN REMOVING SPRINGS, PERSONAL CAN
RESULT.
(1) Release trunk and open trunk lid.
(2) Support trunk lid on a suitable prop device.
(3) Pull split cover from lift spring (Fig. 79).
(4) Using a common plier, disengage spring from
adjustment slot under trunk opening side trough.
(5) Disengage spring from trunk lid hinge.
INSTALLATION
Reverse the preceding operation.
TRUNK LOCK CYLINDER
REMOVAL
(1) Remove trunk latch.
(2) Remove clip holding trunk lock cylinder to
trunk lid.
(3) Pull lock cylinder from trunk lid (Fig. 80).
INSTALLATION
Reverse the preceding operation.
Fig. 78 Trunk Lid
Fig. 79 Trunk Lid Lift Springs
Fig. 80 Trunk Lock Cylinder
PLBODY 23 - 33
REMOVAL AND INSTALLATION (Continued)

TRUNK TRIM PANEL
REMOVAL
(1) Remove fasteners holding trunk trim panel to
vehicle (Fig. 81).
(2) Remove trunk trim panel from vehicle.
INSTALLATION
(1) Position panel to deck lid over the striker.
(2) Install push in fasteners.
(3) Position and tuck the upper flange into existing
trim panel on both sides.
(4) Push the corners in place under seal.
(5) Seat the lower edges of the carpet and smooth
out.
(6) Tuck the full edge of panel under trunk lid
weather-seal lip, being careful not to push seal off.
TRUNK WEATHERSTRIP
REMOVAL
(1) Release trunk lid latch and open trunk lid.
(2) Pull trunk lid weatherstrip form trunk opening
fence (Fig. 82).
(3) Separate weatherstrip from vehicle.
INSTALLATION
Reverse the preceding operation.
UPPER QUARTER TRIMÐ4 DOOR
REMOVAL
(1) Disengage clips holding trim to upper quarter
panel (Fig. 83).
(2) Separate upper trim panel from vehicle.
INSTALLATION
(1) Check to ensure that electric rear window wir-
ing is positioned correctly in the roof channel pro-
vided.(2) Position trim panel in vehicle.
(3) Align locating pins on backside of trim panel to
mating holes in upper quarter panel.
(4) Push clips on trim panel into slots in upper
quarter panel.
WINDOW INNERBELT STABILIZER
REMOVAL
(1) Remove door trim panel.
(2) Remove nut holding inner belt stabilizer to
door panel.
(3) Separate inner belt stabilizer from door. (Fig.
84)
Fig. 81 Trunk Trim Panel
Fig. 82 Trunk Weatherstrip
Fig. 83 Upper Quarter Trim
23 - 34 BODYPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
Reverse the preceding operation. Adjust inner belt
stabilizer against glass with enough tension to allow
free up and down movement.
WINDOW REGULATORÐ2 DOOR
NOTE: Power and manual door glass regulators are
serviced using the same procedures. For power
window motor service procedures, refer to Group
8S, Power Windows.
REMOVAL
(1) Remove door trim panel and water shield.
(2) Disconnect wire connector to power window
motor, if so equipped.
(3) Remove nuts holding regulator lift channel to
door glass (Fig. 85).
(4) Secure door glass in upward position.
(5) Mark position of rear bolt of roller channel to
inner door panel to aid in installation.
(6) Remove bolt holding rear of roller channel to
door panel.
(7) Loosen bolt holding front of roller channel to
door panel.
(8) Separate roller channel from door panel (Fig.
86).
(9) Loosen bolts holding window regulator to inner
door panel.
(10) Separate bolt heads from key-hole slots in
inner door panel.
(11) Remove window regulator through large hole
in inner door panel (Fig. 87) and (Fig. 88).
(12) Remove power window motor from regulator,
if so equipped. Refer to Group 8S for Power Window
Motor procedure.
Fig. 84Fig. 85 Regulator Lift Channel
Fig. 86 Roller Channel
Fig. 87 Manual Window Regulator
PLBODY 23 - 35
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Install power window motor on regulator, if so
equipped. Refer to group 8S for Power Window Motor
procedures.
(2) Move window regulator into position in door
and engage bolt heads into key-hole slots in inner
door panel and tighten bolts.
(3) Install roller channel to door panel.
(4) Install bolt at rear of roller channel. Make sure
that bolt is aligned to mark on inner door panel
made previously.
(5) Tighten front and rear bolts of roller channel.
(6) Install nuts holding regulator lift channel to
door glass.
(7) Adjust door glass as described in this section.
(8) Connect wire connector to power window motor,
if so equipped.
(9) Install door speaker, if so equipped.
(10) Install door trim panel and water shield.
WINDOW REGULATORÐ4 DOOR
NOTE: Power and manual door glass regulators are
serviced using the same procedures. For power
window motor service procedures, refer to Group
8S, Power Windows.
REMOVAL
(1) Remove door trim panel and water shield.
(2) Remove door glass.
(3) Disconnect wire connector to power window
motor, if so equipped.
(4) Remove nuts holding top of regulator to inner
door panel.
(5) Remove nuts holding bottom of regulator to
door panel (Fig. 89) and (Fig. 90).
(6) Loosen bolts holding regulator crank/motor to
door panel.(7) Disengage bolts from key hole slots in door
panel.
(8) Remove window regulator from access hole in
door panel.
(9) Remove power window motor from regulator, if
so equipped. Refer to Group 8S for Power Window
Motor procedures.
INSTALLATION
(1) Install power window motor on regulator, if so
equipped. Refer to Group 8S for Power Window
Motor procedures.
(2) Move window regulator into position in door
and engage bolt heads in key-slots in inner door
panel.
(3) Tighten bolts attaching regulator crank/motor
to door panel.
(4) Install nuts holding top and bottom of window
regulator to door panel.
(5) Install door glass. Refer to procedures in this
section to verify and adjust glass alignment.
Fig. 88 Power Window Regulator
Fig. 89 Front Door Manual Window Regulator
Fig. 90 Front Door Power Window Regulator
23 - 36 BODYPL
REMOVAL AND INSTALLATION (Continued)

(6) Connect wire connector to power window motor,
if so equipped.
(7) Install door speaker, if so equipped.
(8) Install door trim panel and water shield.
ADJUSTMENTS
FRONT DOOR GLASS ADJUSTMENT
UP-STOP ADJUSTMENTS
(1) Remove door trim panel.
(2) Remove water shield as necessary to gain
access to adjuster.
(3) Loosen up-stop nut.
(4) Close door and raise door glass.
(5) Adjust up-stop to achieve proper glass height.
(6) Adjust glass so that a piece of paper can be
pulled between the glass and weatherstrip with some
tension.
NOTE: The top edge of the door glass should be
beneath the lip of the weatherstrip
(7) Tighten fasteners.
TOP OF GLASSÐINBOARD/OUTBOARD
ADJUSTMENTS
(1) Remove door trim panel.
(2) Remove water shield as necessary to gain
access to adjusters.
(3) Using a Snap-ontflare-nut socket (FRXM10),
loosen the lower jack-screw jamb-nuts.
(4) Close door and raise glass.
(5) Using a suitable allen-wrench, rotate jack-
screws to achieve proper in/out positioning at the top
edge of the glass.(6) Adjust glass so that a piece of paper can be
pulled between the glass and weatherstrip with some
tension.
(7) Tighten all fasteners.
GLASSÐFRONT/REAR ADJUSTMENT
(1) Remove door trim panel and water shield.
(2) Lower door glass to bottom of travel to gain
access to glass attachments. (Fig. 93)
(3) Loosen three glass attachment bolts.
(4) Raise glass to top of travel and adjust glass to
fit the B-pillar seal. Glass to B-pillar applique gap
should be approximately 13mm (1/2 inch).
(5) Tighten the two accessible glass fasteners in
the full up position.
(6) Lower door glass to the full down position and
tighten the remaining glass fastener.
Fig. 91 Glass AdjustmentÐ4 Door
Fig. 92 Glass AdjustmentÐ2 Door
Fig. 93 Front door glass
PLBODY 23 - 37
REMOVAL AND INSTALLATION (Continued)

(7) Raise glass to top of travel and verify position-
ing. (Fig. 94)
FRONT DOOR LATCH ADJUSTMENT
(1) Insert a hex-wrench through the elongated hole
in the door end frame near the latch striker opening
(Fig. 95).
(2) Loosen socket head screw on the side of the
latch linkage.
(3) Lift upward on outside door handle and release
it.
(4) Tighten socket head screw on latch.
(5) Verify latch operation.
REAR DOOR GLASS ADJUSTMENT
UP-STOP ADJUSTMENTS
(1) Remove door trim panel.
(2) Remove water shield as necessary to gain
access to adjusters.
(3) Using a Snap-ontflare-nut socket (FRXM10),
loosen up- stop eccentric jamb-nut (Fig. 96).
(4) Using a suitable hex-wrench, rotate up-stop
eccentric to achieve proper glass height.
(5) Adjust glass so that a piece of paper can be
pulled between the glass and weatherstrip with some
tension.
TOP OF GLASSÐINBOARD/OUTBOARD
ADJUSTMENTS
(1) Remove door trim panel.
(2) Remove water shield as necessary to gain
access to adjusters.(3) Using a Snap-ontflare-nut socket (FRXM10),
loosen the lower jack-screw jamb-nuts (Fig. 96).
(4) Using a suitable hex-wrench, rotate jack-screws
to achieve proper tension at the top of the glass.
Fig. 94 Front/Rear Glass Position
Fig. 95 Door Latch Adjustment
23 - 38 BODYPL
ADJUSTMENTS (Continued)

(5) Adjust glass so that a piece of paper can be
pulled between the glass and weatherstrip with some
tension.
REAR DOOR LATCH ADJUSTMENT
(1) Insert a hex-wrench through the elongated hole
in the door end frame near the latch striker opening
(Fig. 97).
(2) Loosen socket head screw on the side of the
latch linkage.
(3) Lift upward on outside door handle and release
it.
(4) Tighten socket head screw on latch.
(5) Verify latch operation.
SPECIFICATIONS
BODY LUBRICATION SPECIFICATIONS
LUBRICATION REQUIREMENTS
Body mechanisms and linkages should be
inspected, cleaned, and lubricated, as required, to
maintain ease of operation and to provide protection
against rust and wear. When performing other
underhood services, the hood latch release mecha-
nism and safety catch should be inspected, cleaned,
and lubricated. During the winter season, external
door lock cylinders should be lubricated to assure
proper operation when exposed to water and ice.
Prior to the application of any lubricant, the parts
concerned should be wiped clean to remove dust and
grit. If necessary, a suitable solvent can be used to
clean the item to be lubricated. After lubricating acomponent, any excess oil or grease should be
removed.
LUBRICANT APPLICATION
DOOR LOCK CYLINDERS
(1) Apply a small amount of lubricant directly into
the lock cylinder.
(2) Apply a small amount of lubricant to the key.
(3) Insert key into lock cylinder and cycle the
mechanism from the locked to the unlocked position.
NOTE: Do not add more lubricant.
(4) Cycle the lock cylinder mechanism several
times to allow the lubricant to flow throughout the
cylinder.
(5) Wipe all lubricant from exterior of lock cylinder
and key.
ALL OTHER BODY MECHANISMS
(1) Clean component as described above.
(2) Apply specified lubricant to all pivoting and
sliding contact areas of component.
LUBRICANT USAGE
ENGINE OIL
²Door HingesÐHinge Pin and Pivot Contact
Areas
²Hood HingesÐPivot Points
²Liftgate Hinges
²Trunk Lid Hinges
Fig. 96 Rear Door Glass AdjustmentÐTypical
Fig. 97 Door Latch Adjustment
PLBODY 23 - 39
ADJUSTMENTS (Continued)