DODGE NEON 1999 Service Repair Manual

MOPARTSPRAY WHITE LUBE OR EQUIVALENT
²Door Check Straps
²Liftgate Latches
²Liftgate Prop Pivots
²Ash Receiver
²Fuel Filler Door Remote Control Latch Mecha-
nism
²Parking Brake Mechanism
²Sliding Seat Tracks
²Trunk Latch
MOPARTMULTI±PURPOSE GREASE OR
EQUIVALENT
²All Other Hood Mechanisms
MOPARTLOCK CYLINDER LUBRICANT OR
EQUIVALENT
²Door Lock Cylinders
²Trunk Lock Cylinder
SPECIAL TOOLS
BODY
STICK, TRIM C 4755
23 - 40 BODYPL
SPECIFICATIONS (Continued)

PAINT
INDEX
page page
GENERAL INFORMATION
AFTERMARKET PAINT REPAIR PRODUCTS . . . 42
BASE COAT/CLEAR COAT FINISH........... 41PAINT CODE........................... 41
PAINTED SURFACE TOUCH-UP............ 41
WET SANDING, BUFFING, AND POLISHING . . . 41
GENERAL INFORMATION
PAINT CODE
A paint code is provided on the body code plate
located in the engine compartment. Refer to the
Introduction section at the front of this manual for
body code plate description. The paint and trim codes
are also included on the Vehicle Safety Label located
on the driver's door end frame.
BASE COAT/CLEAR COAT FINISH
On most vehicles a two-part paint application (base
coat/clear coat) is used. Color paint that is applied to
primer is called base coat. The clear coat protects the
base coat from ultraviolet light and provides a dura-
ble high-gloss finish.
WET SANDING, BUFFING, AND POLISHING
Minor acid etching, orange peel, or smudging in
clear coat or single-stage finishes can be reduced
with light wet sanding, hand buffing, and polishing.
If the finish has been wet sanded in the past, it
cannot be repeated. Wet sanding operation
should be performed by a trained automotive
paint technician.
CAUTION: Do not remove clear coat finish, if
equipped. Base coat paint must retain clear coat for
durability.
PAINTED SURFACE TOUCH-UP
When a painted metal surface has been scratched
or chipped, it should be touched-up as soon as possi-ble to avoid corrosion. For best results, use Mopart
Scratch Filler/Primer, Touch-Up Paints and Clear Top
Coat. Refer to Introduction group of this manual for
Body Code Plate information.
TOUCH-UP PROCEDURE
(1) Scrape loose paint and corrosion from inside
scratch or chip.
(2) Clean affected area with MopartTar/Road Oil
Remover, and allow to dry.
(3) Fill the inside of the scratch or chip with a coat
of filler/primer. Do not overlap primer onto good sur-
face finish. The applicator brush should be wet
enough to puddle-fill the defect without running. Do
not stroke brush applicator on body surface. Allow
the filler/primer to dry hard.
(4) Cover the filler/primer with color touch-up
paint. Do not overlap touch-up color onto the original
color coat around the scratch or chip. Butt the new
color to the original color, if possible. Do not stroke
applicator brush on body surface. Allow touch-up
paint to dry hard.
(5) On vehicles without clear coat, the touch-up
color can be lightly wet sanded (1500 grit) and pol-
ished with rubbing compound.
(6) On vehicles with clear coat, apply clear top coat
to touch-up paint with the same technique as
described in Step 4. Allow clear top coat to dry hard.
If desired, Step 5 can be performed on clear top coat.
PLBODY 23 - 41

AFTERMARKET PAINT REPAIR PRODUCTS
EXTERIOR COLORS
EXTERIOR
COLORCHRY
CODE*PPG BASF DuPONTS-W ACME
M-SAKZO NOBEL
SIKKENS
Alpine Green
Pearl CoatVGT 5358 28061 B9843 54162 CHA98´VGT
Black Clear
CoatDX8 9700 15214 F0204 35858 CHA85´DX8
90-5950
Bright Jade
Satin GlowSQM 18885 26094 B9620 51534 CHA96´SQM
Bright Platinum
Met. Clear CoatMS4 4820 24082 B9462 48823 CHA94´MS4
Bright White
Clear CoatGW7 4037 18238 B8833 37298 CHA88´GW
Brilliant Blue
Pearl CoatPCH 4784 24073 B9452 48538 CHA94´PCH
Deep Amethyst
Pearl CoatTCN 5246 27038 B9736 52566 CHA97´TCN
Flame Red
Clear CoatPR4 4679 23043 B9326 4691 CHA93´PR4
Forest Green
Pearl CoatSG8 47439 26078 B9609 5106 CHA95´SG8
Intense Blue
Pearl CoatVB3 5357 28074 B9822 54468 CHA98´VB3
Lapis Blue
Clear CoatRC4 4935 24098 B9531 50218 CHA95´RC4
Strawberry
Pearl CoatPRE 4791 24074 B9454 48542 CHA94´PRE
*Herberts Standox and Spies Hecker use the Chrysler paint code as listed on the Body Code Plate.
INTERIOR COLORS
INTERIOR COLORCHRY
CODEPPG BASF DuPONTS-W
ACME
M-SAKZO
NOBEL
SIKKENS
Agate AZ 9856/2-
146122135 C9208 45994 CHALAZI
Camel K5 27731 26120 C9603 51541 CHARK5I
23 - 42 BODYPL
GENERAL INFORMATION (Continued)

STATIONARY GLASS
INDEX
page page
DESCRIPTION AND OPERATION
SAFETY PRECAUTIONS.................. 43
REMOVAL AND INSTALLATION
QUARTER GLASS....................... 45REAR WINDOW......................... 46
WINDSHIELD........................... 43
DESCRIPTION AND OPERATION
SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A SYS-
TEM. USE GLASS CLEANER, GLASS PREP SOL-
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND
PINCHWELD (FENCE) PRIMER PROVIDED BY THE
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL
INTEGRITY COULD BE COMPROMISED.
CHRYSLER DOES NOT RECOMMEND GLASS
ADHESIVE BY BRAND. TECHNICIANS SHOULD
REVIEW PRODUCT LABELS AND TECHNICAL DATA
SHEETS, AND USE ONLY ADHESIVES THAT THEIR
MANUFACTURES WARRANT WILL RESTORE A
VEHICLE TO THE REQUIREMENTS OF FMVSS 212.
TECHNICIANS SHOULD ALSO INSURE THAT PRIM-
ERS AND CLEANERS ARE COMPATIBLE WITH THE
PARTICULAR ADHESIVE USED.
BE SURE TO REFER TO THE URETHANE MANU-
FACTURER'S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
It is difficult to salvage a windshield during the
removal operation. The windshield is part of the
structural support for the roof. The urethane bonding
used to secure the windshield to the fence is difficult
to cut or clean from any surface. If the moldings are
set in urethane, it would also be unlikely they could
be salvaged. Before removing the windshield, check
the availability of the windshield and moldings from
the parts supplier.
REMOVAL AND INSTALLATION
WINDSHIELD
The urethane adhesive holding the windshield to
the opening pinch weld (fence) can be cut using a
sharp cold knife from the exterior of the vehicle.
Using the cold knife method is effective if the wind-
shield is already broken. If the glass must be sal-
vaged, cutting the urethane adhesive from the
interior of the vehicle using a reciprocating or oscil-
lating power knife is recommended.
WINDSHIELD REMOVAL ± EXTERIOR METHOD
(1) Remove inside rear view mirror.
(2) Remove windshield wiper arms.
(3) Remove cowl cover.
(4) Place protective covers over instrument panel
and hood.
PLBODY 23 - 43

(5) Remove windshield moldings (Fig. 1) using a
suitable hook tool and trim stick.
(6) Using a sharp cold knife, cut urethane adhe-
sive holding the windshield to the A-pillars, roof
header and cowl pinch weld fences (Fig. 2). A power
cutting device can be used if available.
(7) Separate windshield from vehicle.
WINDSHIELD REMOVAL ± INTERIOR METHOD
(1) Remove inside rear view mirror.
(2) Remove instrument panel top cover, refer to
Group 8E, Instrument Panel.
(3) Remove A-pillar trim covers.
(4) Place protective covers over instrument panel
and hood.
(5) Using a reciprocating or oscillating power
knife, cut urethane adhesive holding the windshield
to the A-pillars, roof header and cowl pinch weld
fences. Refer to instructions provided with the equip-
ment being used.
(6) Separate windshield from vehicle.
WINDSHIELD INSTALLATION
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 wind-
shield opening.
(1) Place replacement windshield into windshield
opening and position glass in the center of the open-
ing against the support spacers.
(2) Verify the glass lays evenly against the pinch
weld fence at the sides, top and bottom of the
replacement windshield. If not, the pinch weld fence
must be formed to the shape of the new glass.
(3) Mark the glass at the support spacers with a
grease pencil or pieces of masking tape and ink pen
to use as a reference for installation (Fig. 3).
(4) Remove replacement windshield from wind-
shield 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. 4).
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 molding to perimeter of windshield.
(8) 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.
(9) Apply Glass Primer 25 mm (1 in.) wide around
perimeter of windshield. Allow at least three minutes
drying time.
(10) Using a razor knife, remove as much original
urethane as possible. Do not damage paint on wind-
shield fence.
(11) Apply pinch weld primer 15 mm (.75 in.) wide
around the windshield fence. Allow at least three
minutes drying time.
(12) If a low viscosity urethane adhesive is used,
install compression spacers on the fence around the
windshield opening (Fig. 5).
(13) Apply a 10 mm (0.4 in.) bead of urethane on
center line of windshield fence.
(14) With the aid of a helper, position the wind-
shield over the windshield opening. Align the refer-
ence marks at the bottom of the windshield to the
support spacers.
Fig. 1 Windshield Molding
Fig. 2 Cut Urethane Around Windshield
23 - 44 BODYPL
REMOVAL AND INSTALLATION (Continued)

(15) Slowly lower windshield glass to windshield
opening fence. Guide the molding into proper position
as necessary. Push windshield inward molding is
flush to roof line and A-pillars (Fig. 6).
(16) Clean access urethane from exterior with
Mopart, Super Clean or equivalent.
(17) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)
masking tape spaced 250 mm (10 in.) apart to hold
molding in place until urethane cures.
(18) Install cowl cover and wipers.
(19) Install inside rear view mirror.
(20) After urethane has cured, remove tape strips
and water test windshield to verify repair.
QUARTER GLASS
REMOVAL
(1) Remove quarter trim panel.
(2) Remove nuts holding quarter glass to quarter
panel opening.
(3) Remove B-pillar applique.(4) Using a razor knife from inside of vehicle, cut
butyl tape adhesive around quarter glass while push-
ing outward on glass.
(5) Separate quarter glass from vehicle (Fig. 7).INSTALLATION
(1) Clean old butyl tape adhesive from around
quarter glass opening in quarter panel.
(2) If original quarter glass is reused, clean old
butyl from around glass.
Fig. 3 Center Windshield and Mark at Support
Spacers
Fig. 4 Work Surface Set up and Molding Installation
Fig. 5 Position Urethane Compression Spacers
Fig. 6 Lower Windshield Into Position
Fig. 7 Quarter Glass
PLBODY 23 - 45
REMOVAL AND INSTALLATION (Continued)

(3) Prime perimeter of quarter glass fence in quar-
ter panel opening with black-out primer.
(4) Prime perimeter of quarter glass with black-out
primer.
(5) Install a 5/16 bead of round butyl tape around
perimeter of quarter glass.
(6) Place quarter glass into opening in quarter
panel.
(7) Install nuts to hold quarter glass to quarter
panel opening.
(8) Install B-pillar applique.
(9) Install quarter trim panel.
REAR WINDOW
Refer to the windshield paragraph of this section
for a description of tools and adhesive systems that
are recommended for use in this procedure.
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT. BE SURE TO REFER TO THE URE-
THANE MANUFACTURER'S DIRECTIONS FOR CUR-
ING TIME SPECIFICATIONS, AND DO NOT USE
ADHESIVE AFTER ITS EXPIRATION DATE.
CAUTION: Open the left front door glass before
installing the rear window to avoid pressurizing the
passenger compartment if a door is slammed
before the urethane bonding is fully cured. Water
leaks can result
REAR WINDOW REMOVAL
(1) Remove rear window moldings.
(2) Remove upper quarter trim panel.
(3) Disengage wire connectors from rear window
defogger.
WARNING: WEAR EYE AND HAND PROTECTION
WHEN HANDLING SAFETY GLASS. PERSONAL
INJURY CAN RESULT.CAUTION: Do not damage body or trim finish
when cutting out glass or applying fence primer.
(4) Cut the urethane around the perimeter of the
rear window glass. Refer to Windshield section of
this group for proper procedures.
(5) Separate the rear window from the vehicle.
REAR WINDOW INSTALLATION
(1) Prepare the work area, window fence, and
glass the same way as described in the Windshield
section of this group.
(2) Place fence spacers at the locations shown (Fig.
8).
(3) Install the rear window molding on glass.
(4) Apply a 10 mm (0.4 in.) bead of urethane
around the perimeter of the glass.
(5) Install the glass in the same manner described
in the Windshield section of this group (Fig. 8).
(6) Connect rear window defogger wiring and inte-
rior trim.
(7) After urethane has cured, water test rear win-
dow to verify repair. Verify rear window defogger
operation, see Group 8N, Rear Window Defogger.
Fig. 8 Rear Window Glass
23 - 46 BODYPL
REMOVAL AND INSTALLATION (Continued)

SUNROOF
INDEX
page page
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES............... 47
SUNROOF DIAGNOSIS................... 47
REMOVAL AND INSTALLATION
SUNROOF CABLES...................... 48
SUNROOF COMPONENTS................ 49
SUNROOF DRIVE MOTOR................. 49
SUNROOF GLASS PANEL................. 49SUNROOF GUIDE AND MECHANISM
ASSEMBLY........................... 49
SUNROOF MODULE..................... 50
SUNROOF PROCEDURE INFORMATION...... 48
SUNROOF SUNSHADE................... 50
SUNROOF WIND DEFLECTOR............. 51
ADJUSTMENTS
SUNROOF GLASS HEIGHT ADJUSTMENT.... 51
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
Before beginning sunroof diagnostics verify that all
other power accessories are in proper operating con-
dition. If not, a common electrical problem may exist.
Refer to the Wiring Diagrams section of this publica-tion for circuit, splice and component descriptions.
Check the condition of the circuit protection (fuses,
circuit breakers or fuse links). Inspect all wiring con-
nector pins for proper engagement and continuity.
Check for battery voltage at the power sunroof con-
trol switches. If battery voltage is detected at the
control switches, proceed with the following tests.
SUNROOF DIAGNOSIS
SYMPTOM POSSIBLE CAUSE
Sunroof motor inoperative.²Contaminated or corroded slides and channels.
²Binding cable or linkage.
²Faulty circuit ground.
²Faulty power circuit to sunroof drive motor.
²Faulty sunroof drive motor.
²Faulty sunroof motor connector.
Audible whine when switch is depressed,
sunroof does not operate.²Faulty motor drive clutch.
²Binding linkage.
²Faulty sunroof motor connections.
Sunroof opens, but does not close.²Binding linkage.
²Faulty circuit.
²Faulty switch.
Sunroof vents, but does not open.²Binding linkage.
²Faulty circuit.
²Faulty switch.
Sunroof does not vent²Binding cable.
²Faulty circuit.
²Faulty switch.
Sunroof vents and opens but does not
close²Binding linkage.
²Faulty circuit.
²Faulty switch.
Sunroof water leak.²Drain tubes clogged or kinked.
²Glass panel improperly adjusted.
²Faulty glass panel seal.
PLBODY 23 - 47

SYMPTOM POSSIBLE CAUSE
Wind noise from sunroof.²Front of glass panel too high or rear too low.
²Glass panel not centered in opening.
²Faulty glass panel seal.
Glass panel hangs up or snaps between
vent and open.²Glass panel improperly adjusted.
²Glass panel seal has inconsistent compression.
Rattles from open sunroof while driving²Loose attaching hardware.
²Weak springs on wind deflector.
²Sunshade out of the track.
Rattles from closed sunroof while driving²Loose attaching hardware.
²Wind deflector contacting glass panel or drain trough.
²Sunshade out of the track.
REMOVAL AND INSTALLATION
SUNROOF PROCEDURE INFORMATION
The numbered call-outs in the following ser-
vice procedures refer the numbered parts
found in the figure at the end of this section.
SUNROOF CABLES
REMOVAL
(1) Remove sunroof glass panel (4). Refer to proce-
dure found in this section.
(2) Cycle the sunroof mechanism to the full for-
ward position.
CAUTION: Do not remove sunroof drive motor
unless sunroof mechanism is in the full forward
position.
(3) Remove sunroof drive motor (10). Refer to pro-
cedure found in this section.
(4) Remove front locator (7 or 8) for appropriate
sunroof cable.
(5) Disengage sunroof cable from sunroof mecha-
nism (9).
(6) Pull sunroof cable from drive tube (2 or 3).
INSTALLATION
(1) Push sunroof cable through drive tube (2 or 3).(2) Engage sunroof cable into sunroof mechanism
(9) making sure cable connecting rod is rotated at a
45 degree angle towards inside of vehicle (Fig. 1).
(3) Install front locator (7 or 8) over sunroof cable.
Moving the sunroof mechanism rearward slightly will
ease locator installation.
(4) Move sunroof to full forward position.
(5) Install sunroof drive motor (10).
(6) Install sunroof glass panel (5). Refer to proce-
dure found in this section.Fig. 1 Front View of Guide
23 - 48 BODYPL
DIAGNOSIS AND TESTING (Continued)

SUNROOF COMPONENTS
SUNROOF DRIVE MOTOR
CAUTION: Do not cycle the sunroof drive motor
prior to installation. The drive motor is shipped in
the closed position. The sunroof vent position is
programmed into the drive motor and is dependent
upon the drive motor closed position. If the drive
motor and the sunroof mechanism are not both in
the closed position, the sunroof vent height will not
be correct.
REMOVAL
(1) Remove headlining until the sunroof drive
motor (10) can be accessed.
(2) If the drive motor is to be reused, cycle the
sunroof to the full forward position.
(3) Disconnect wire harness connector from motor.
(4) Remove the three screws attaching drive motor
to sunroof module bracket.
(5) Separate drive motor (10) from bracket.
Fig. 2 Sunroof Components
Item Number Component Name Item Number Component Name
1 Drive Tube Locator 8 Locator R.H.
2 Drive Tube L.H. 9 Mechanism
3 Drive Tube R.H. 10 Drive Motor
4 Glass Reinforcment
Panel11 Sunshade
5 Guide 12 Tray Assembly
6 Sunshade Guide 13 Wind Deflector
7 Locator L.H.
PLBODY 23 - 49
REMOVAL AND INSTALLATION (Continued)