DODGE NEON 1999 Service Repair Manual

(14) Remove headlining through door opening (Fig.
45).
INSTALLATION
(1) Position headlining in vehicle.
(2) Install sun visor hooks.
(3) Install coat hooks, if vehicle is a 4 door.
(4) Install push±in fastener at rear of headlining.
(5) Install assist handles, if so equipped.
(6) Install push±in fastener holding headliner wir-
ing to C±pillar.
(7) Engage dome lamp wire connector, at rear of
headlining.
(8) If vehicle is equipped with a sunroof;
(a) Install screw holding switch pod retainer to
roof.
(b) Connect sunroof switch pod wire connectors.
(c) Install sunroof switch pod.
(d) Install trim welt around sunroof opening
(Fig. 44).
(e) Close sunroof.
(9) Install (upper) quarter panel trim panel.(10) Install B-pillar trim panels, if vehicle is a 4
door.
(11) Install A-pillar trim covers.
(12) Install sun visors, lighted vanity mirror wire
connector, if so equipped, and screws holding sun
visors to roof header panel.
HOOD
REMOVAL
(1) Raise hood to full up position.
(2) Disengage under hood lamp wire connector
from engine compartment wire harness.
(3) Mark all bolt and hinge attachment locations
with a grease pencil or other suitable device to pro-
vide reference marks for installation. When installing
hood, align all marks and secure bolts. The hood
should be aligned to 4 mm (0.160 in.) gap to the front
fenders and flush across the top surfaces along fend-
ers.
(4) Remove the top bolts holding hood to hinge and
loosen the bottom bolts until they can be removed by
hand.
(5) With assistance from a helper at the opposite
side of the vehicle to support the hood, remove bot-
tom bolts holding hood to hinge.
(6) Separate the hood from the vehicle.
INSTALLATION
(1) Place hood in position on vehicle. With assis-
tance from a helper at the opposite side of the vehicle
to support the hood, install bottom bolts to hold hood
to hinge finger tight.
(2) Install top bolts to hold hood to hinge finger
tight.
(3) Position bolts at marks and tighten bolts. The
hood should be aligned to 4 mm (0.160 in.) gap to the
front fenders and flush across the top surfaces along
fenders.
(4) Engage under hood lamp wire connector to
engine compartment wire harness.
(5) Verify hood operation and alignment.
HOOD HINGE
REMOVAL
(1) Support hood on the side that requires hinge
replacement.
(2) Mark all bolt and hinge attachment locations
with a grease pencil or other suitable device to pro-
vide reference marks for installation. When installing
hood hinge, align all marks and secure bolts. The
hood should be aligned to 4 mm (0.160 in.) gap to the
front fenders and flush across the top surfaces along
fenders. Shims can be added or removed under hood
hinge to achieve proper hood height.
(3) Remove bolts holding hood to hinge.
Fig. 44 Sunroof Opening Trim Welt
Fig. 45 Headlining
23 - 20 BODYPL
REMOVAL AND INSTALLATION (Continued)

(4) Remove bolts holding hood hinge to front
fender flange and separate hinge from vehicle. If nec-
essary, paint new hinge before installation.
INSTALLATION
(1) If necessary, paint new hinge before installa-
tion.
(2) Place hinge in position on vehicle.
(3) Install bolts to hold hood hinge to front fender
flange.
(4) Install bolts to hold hood to hinge.
(5) Align all marks and secure bolts. The hood
should be aligned to 4 mm (0.160 in.) gap to the front
fenders and flush across the top surfaces along fend-
ers. Shims can be added or removed under hood
hinge to achieve proper hood height.
(6) Remove support from under hood and verify
hood operation.
HOOD LATCH
REMOVAL
(1) Release hood latch and open hood.
(2) Support hood on prop rod.
(3) Remove grille.
(4) Remove screws holding hood latch to radiator
closure panel (Fig. 46).
(5) Separate hood latch from closure panel.
(6) Disengage remote release cable from latch.
INSTALLATION
(1) Engage remote release cable into latch.
(2) Place hood latch onto radiator closure panel.
(3) Install bolts holding latch to closure panel.(4) Install grille.
(5) Close hood and verify alignment of hood and
that latch is securely engaged.
HOOD RELEASE CABLE
REMOVAL
(1) Disconnect remote hood release cable from
hood latch.
(2) Remove left front cowl trim panel.
(3) Remove screws holding hood release handle to
cowl panel (Fig. 47).
(4) Disengage rubber grommet from dash panel
behind instrument panel.
(5) Pull release cable through hole in dash panel.
(6) Separate cable and handle from vehicle.
INSTALLATION
(1) Assemble cable and handle onto vehicle.
(2) Push release cable through hole in dash panel.
(3) Engage rubber grommet into dash panel.
(4) Install screws holding hood release handle to
cowl panel.
(5) Install left front cowl trim panel.
(6) Connect remote hood release cable to hood
latch.
(7) Close hood and verify operation.
LOCK BUTTON BELL-CRANK
REMOVAL
(1) Remove door trim panel.
(2) Disengage clip holding lock linkage to bell-
crank.
Fig. 46 Hood Latch
Fig. 47 Hood Release Cable
PLBODY 23 - 21
REMOVAL AND INSTALLATION (Continued)

(3) Rotate bell-crank until retaining ears align
with slots in door panel.
(4) Separate bell-crank from door (Fig. 48).
INSTALLATION
Reverse the preceding operation.
LOWER QUARTER TRIMÐ4 DOOR
REMOVAL
(1) Remove upper quarter trim panel.
(2) Remove rear seat cushion and back.
(3) Disengage clips holding trim to lower quarter
panel.
(4) Remove seat belt from slot in trim panel.
(5) Separate lower quarter trim from vehicle (Fig.
49).
INSTALLATION
(1) Position lower quarter trim panel to vehicle.
(2) Install seat belt to slot in trim panel.
(3) Align locating pins on backside of trim panel to
mating holes in inner quarter panel.(4) Press clips on trim panel into slots in inner
quarter panel.
(5) Install rear seat back and cushion.
(6) Install upper quarter trim panel.
PARCEL SHELF TRIM
REMOVAL
(1) Remove upper quarter trim from one side of
vehicle.
(2) Remove rear seat cushion and back.
(3) Remove bolts holding rear seat shoulder belt
lower anchors to floor pan.
(4) Disengage seat belt bezel from parcel shelf.
(5) Separate parcel shelf trim from vehicle.
INSTALLATION
Reverse the preceding operation.
QUARTER TRIM PANELÐ2 DOOR
REMOVAL
(1) Remove rear seat cushion and back.
(2) Slide lower seat belt anchor cover up the web-
bing to expose the belt.
(3) Remove bolt holding lower seat belt anchor to
floor.
(4) Separate seat belt from floor.
(5) Remove screw holding coat hook to top of quar-
ter trim panel.
(6) Disengage hidden clips holding quarter trim
panel to inner quarter panel. (Fig. 51)
(7) Separate trim from quarter panel.
(8) Feed seat belt webbing through access hole in
trim panel.
(9) Separate quarter trim panel from vehicle.
INSTALLATION
(1) Feed seat belt webbing through access hole in
trim panel.
Fig. 48 Lock Button Bell-crank
Fig. 49 Lower Quarter TrimÐ4 Door
Fig. 50 Parcel Shelf Trim
23 - 22 BODYPL
REMOVAL AND INSTALLATION (Continued)

(2) Position trim panel near inner quarter panel.
(3) Align locating pins on backside of trim panel to
mating holes in inner quarter panel.
(4) Push clips on trim panel into slots in inner
quarter panel starting with the clips located near
locating pins.
(5) Install screw holding coat hook to top of quar-
ter trim panel.
(6) Install bolt securing seat belt anchor to floor.
(7) Slide lower seat belt anchor cover down to
cover anchor bolt.
(8) Install rear seat cushion and seat back.
REAR DOOR GLASS
REMOVAL
(1) Remove door trim panel and water shield.
(2) Remove inner door belt weatherstrip.
(3) Loosen door glass jounce bumper.
(4) Lower door glass to bottom of door.
(5) Remove nuts holding door glass to window reg-
ulator lift plate (Fig. 52).
(6) Disengage door glass from regulator.
(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.
(2) Install nuts holding door glass to window reg-
ulator lift plate.
(3) Raise glass and tighten window inner belt sta-
bilizer.
(4) Install inner door belt weatherstrip, water-
shield, and door trim panel.
(5) Operate window and check for interference.
Adjust glass as necessary.
REAR DOOR INNER BELT WEATHERSTRIP
REMOVAL
(1) Remove door trim panel.
(2) Pull weatherstrip from top of door panel (Fig.
53).
(3) Separate weatherstrip from door.
INSTALLATION
(1) Place inner belt weatherstrip in position on
door.
(2) Push down on weatherstrip to engage channel
to door panel.
(3) Install door trim panel.
Fig. 51 Quarter Trim PanelFig. 52 Rear Door Glass
Fig. 53 Rear Door Inner Belt Weatherstrip
PLBODY 23 - 23
REMOVAL AND INSTALLATION (Continued)

REAR DOOR INTERLOCK LATCH STRIKER
REMOVAL
(1) Release door latch and open rear door.
(2) Mark outline of interlock striker on C-pillar to
aid installation.
(3) Remove interlock striker from vehicle (Fig. 54).
INSTALLATION
Reverse the preceding operation.
REAR DOOR LATCH
REMOVAL
(1) Remove door trim panel and water shield.
(2) Close door glass.
(3) Disconnect lock and latch rods from door latch.
(4) Disengage wire connector from power door lock
motor, if equipped.
(5) Remove screws holding latch to door end frame
(Fig. 55).
(6) Separate door latch from vehicle.
INSTALLATION
CAUTION: Do not close door before adjusting the
door latch. Door may fail to open.
(1) Position door latch on vehicle and install
screws holding latch to door end frame.
(2) Engage wire connector to power door lock
motor, if so equipped.
(3) Connect lock and latch rods to door latch.
(4) Install watershield and door trim panel.
REAR 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. 56).
(3) Separate door latch striker from vehicle.
INSTALLATION
Reverse the preceding operation.
REAR DOOR LOCK BELL CRANK
REMOVAL
(1) Remove door trim panel and water shield.
(2) Disengage clips holding lock rods to bell crank.
(3) Separate lock rods from bell crank.
(4) Rotate bell crank to align retaining tabs to
slots in door panel.
(5) Separate bell crank from door.
INSTALLATION
Reverse the preceding operation.
Fig. 54 Rear Door Interlock Latch Striker
Fig. 55 Rear Door Latch
Fig. 56 Rear Door Latch Striker
23 - 24 BODYPL
REMOVAL AND INSTALLATION (Continued)

REAR 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. 57).
INSTALLATION
Reverse the preceding operation.
REAR DOOR TRIM
REMOVAL
(1) Release door latch and open door.
(2) Lower window glass.
(3) Remove window regulator crank.
(4) Remove screw from inside arm rest pull cup.
(5) Remove screw from behind inside latch release
handle (Fig. 58).
CAUTION: Pulling on trim panel to disengage fas-
teners will damage the trim panel.
NOTE: Use a fork-type push-in fastener removal
tool.
(6) Disengage push-in fasteners holding trim to
door panel around perimeter of trim panel.
(7) Disengage trim panel from retainer channel in
inner belt weather-strip at top of door by lifting while
jiggling.
(8) Tilt top of trim panel away from door and dis-
engage clip holding latch rod to handle.
(9) Separate latch rod from handle.
(10) Remove trim panel from door.
INSTALLATION
(1) Replace any damaged or missing push in fas-
teners from around perimeter of door trim panel.
(2) Place trim panel in position on door.
(3) Insert latch rod into handle and engage clip.
(4) Engage trim panel into retainer channel at top
of door.
(5) Locate door trim panel to inner door panel by
aligning locating pins on backside of trim panel to
mating holes in inner door panel.
(6) Install push-in fasteners to attach trim to door
panel around perimeter of trim panel.
(7) Install screw behind inside latch release han-
dle.
(8) Install screw inside arm rest pull cup.
(9) Install window regulator crank.
REAR DOOR WINDOW REGULATOR
REMOVAL
(1) Remove door trim panel and watershield.
(2) Remove door glass.
(3) Loosen bolts holding window regulator crank/
motor to door panel.
(4) Disengage bolt heads from keyhole slots in door
panel.
(5) Loosen bolts holding window regulator lift bar
to door panel.
Fig. 57 Rear Door Outer Belt WeatherstripFig. 58 Rear Door Trim
PLBODY 23 - 25
REMOVAL AND INSTALLATION (Continued)

(6) Disengage bolt heads from keyhole slots in door
panel (Fig. 59).
(7) Remove window regulator from door through
access hole in inner panel.
INSTALLATION
(1) Move window regulator into position and
engage bolt heads into key-hole slots in inner door
panel.
(2) Tighten bolts holding window regulator lift bar
to inner door panel.
(3) Engage window regulator crank/motor bolts
into key-hole slots in door panel.
(4) Tighten window regulator crank/motor bolts.
(5) Install door glass, watershield, and door trim
panel.
REAR SEAT BACK
REMOVAL
(1) Remove rear seat cushion.
(2) Remove bolts holding rear seat back and seat
belts to floor.
(3) Push rear seat back upward to disengage hooks
at top of seat back (Fig. 60).
(4) Separate rear seat from vehicle.
INSTALLATION
(1) Move rear seat back into position in vehicle.
(2) Push seat back downward to engage hooks at
top of seat back.
(3) Install bolts holding rear seat back and seat
belts to floor.
NOTE: The torque specification for the inner seat
belt/rear seat back retaining bolts is 57 N´M (42 ft.
lbs.).
(4) Install rear seat cushion.
REAR SEAT BELT BUCKLE
REMOVAL
(1) Remove rear seat cushion.
(2) Remove rear seat back.
(3) Separate rear seat belt buckle from vehicle.
INSTALLATION
Reverse the preceding operation.
REAR SEAT BELT RETRACTOR
REMOVAL
(1) Remove rear seat cushion and back.
(2) Remove seat belt bezel from parcel shelf cover.
(3) Remove rear seat closure panel silencer pad as
necessary to gain access to retractor.
(4) Remove bolt holding seat belt lower anchor to
floor.
(5) Remove bolt holding retractor to rear seat clo-
sure panel (Fig. 61).
(6) Push seat belt bezel and buckle stab through
access hole in parcel shelf.
(7) From in luggage compartment, separate rear
seat belt retractor from vehicle.
INSTALLATION
Reverse the preceding operation.
REAR SEAT CUSHION
REMOVAL
(1) Pull upward at each end of the rear seat cush-
ion to disengage retainer loops from cups in floor.
(2) Separate rear seat cushion from vehicle (Fig.
62).
INSTALLATION
(1) Place rear seat cushion in position under bot-
tom of seat back.
Fig. 59 Rear Door Window Regulator
Fig. 60 Rear Seat Back
23 - 26 BODYPL
REMOVAL AND INSTALLATION (Continued)

(2) Position inboard seat belts on top of seat cush-
ion.
(3) Guide seat cushion loops into retainer cups in
floor pan.
(4) Push downward on the front corners of the seat
cushion to engage retainers.
REAR SPOILER
REMOVAL
(1) Release trunk latch and open trunk lid.
(2) Remove nuts holding spoiler to trunk lid.
(3) Separate spoiler from trunk lid (Fig. 63).
INSTALLATION
Apply water sealing putty around spoiler mounting
studs and reverse the preceding operation.
REAR VERTICAL GUIDE BAR
REMOVAL
(1) Remove door trim panel and water shield.
(2) Remove nut holding top of rear guide bar to
inner door panel.
(3) 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.
(4) Remove rear vertical guide bar through large
access hole in inner door panel (Fig. 64).
INSTALLATION
Reverse the preceding operations and verify glass
alignment.
Fig. 61 Rear Seat Belt Retractor
Fig. 62 Rear Seat Cushion
Fig. 63 Rear Spoiler
Fig. 64 Rear Vertical Guide Bar
PLBODY 23 - 27
REMOVAL AND INSTALLATION (Continued)

ROOF APERTURE (RAP) MOLDING
The RAP molding is set in urethane adhesive. The
RAP molding is difficult to salvage during removal.
Verify part availability before proceeding with
removal procedure. The temperature in the work
area and the vehicle should be at least 21ÉC (70ÉF) to
avoid damaging the rear window and windshield
moldings. Apply masking tape to surrounding area of
the RAP molding to protect the finish.
REMOVAL
(1) Using a trim stick, gently lift rear window
molding upward to gain access to end of RAP mold-
ing.
(2) Using a sharp hook tool, pierce the rear end of
the molding.
(3) Lift the rear of the RAP molding upward until
it clears the rear window molding.
(4) Using a common plier, pull the RAP molding
forward to separate molding from urethane bonding.
(5) Separate RAP molding from vehicle.
INSTALLATION
(1) Using a sharpened trim stick, scrape urethane
bonding material from the roof seam trough.
(2) Using touch-up paint, repair scratches in roof
seam trough to prevent corrosion.
(3) Inspect the bottom of the roof seam trough for
gaps in caulking. Repair gaps with suitable seam
sealer following manufacturers instructions.
(4) Apply black-out primer to bottom of roof seam
trough. Allow at lease three minutes before bonding
is applied.
(5) Install RAP molding into the roof seam trough
and position molding so both ends are covered by the
glass moldings. If the molding will not lay flat on the
bottom of the trough, trim the ends of the molding
until proper fit achieved.
(6) Using a suitable marking pencil, mark an
index line across the RAP molding and the adjacent
surfaces.
(7) Remove the RAP molding from the roof seam
trough.
(8) Applya5mm(0.2 in.) bead of urethane adhe-
sive on the bottom/center of the trough along the
entire length.
(9) Place RAP molding in position in roof seam
trough (Fig. 65).
(10) Insert both ends of RAP molding under glass
moldings.
(11) Align index marks across trough and molding.
(12) Gently press RAP molding into urethane
adhesive until molding lays smooth and flat.
(13) Remove protective tape from around the RAP
molding.
(14) Clean excess urethane from exterior with
Mopar, Super Clean or equivalent.(15) Apply a length of 50 mm (2 in.) masking tape
over the RAP molding to retain the molding until the
urethane adhesive is cured. Curing time for most
urethane adhesive is at least 24 hours.
ROOF RACK
The roof rack insulator gasket is bonded to the
base of the side rail. If the gasket comes loose during
servicing, secure the gasket to the side rail with
Mopar, Bond-all Gel Adhesive or equivalent.
REMOVAL
(1) Remove screws holding roof rack side rails to
the roof panel (Fig. 66).
(2) Separate roof rack from vehicle.
INSTALLATION
Reverse the preceding operation.
ROOF RACK CROSS RAILS
The roof rack side rail do not have to be removed
to replace the cross rails.
Fig. 65 RAP Molding
Fig. 66 Roof Rack
23 - 28 BODYPL
REMOVAL AND INSTALLATION (Continued)

REMOVAL
(1) Remove screws holding cross rail to the side
rails.
(2) Separate the cross rail from the roof rack.
INSTALLATION
Reverse the preceding operation.
ROOF RAIL WEATHER-STRIP ± TWO DOOR
REMOVAL
(1) Using a fork tool C-4829, Disengage push-in
fasteners holding bottom of weather-strip to B-pillar.
(2) Disengage push-in fasteners holding bottom of
weather-strip to A-pillar (Fig. 68).
(3) Pull roof rail weather-strip from retainer chan-
nel.
INSTALLATION
Reverse the preceding operation. Zip roof rail
weather-strip into retainer channel using a suitable
awl (Fig. 69).
ROOF RAIL WEATHER-STRIP FOUR DOOR
REMOVAL
(1) Remove B-pillar applique.
(2) Remove push-in fasteners holding bottom of
roof rail weather-strip to B-pillar.
(3) Remove push-in fastener holding rearward end
of weather-strip to quarter panel.
(4) Remove push-in fasteners holding weather-
strip to front door hinge pillar.
(5) Pull weather-strip from retainer channel under
drip rail (Fig. 70).
(6) Pull weather-strip from B-pillar channels.
(7) Separate roof rail weather-strip from vehicle.
Fig. 67 Roof Rack Cross Rails
Fig. 68 Roof Rail Weather-strip
Fig. 69 Install Roof Rail Weather-strip
Fig. 70 Roof Rail Weather-strip
PLBODY 23 - 29
REMOVAL AND INSTALLATION (Continued)