light DODGE NEON 1999 Service Repair Manual

(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)

(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)

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

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)

INSTALLATION
(1) With the aid of a helper, hold the sunroof glass
panel in the closed position and engage the drive
motor (10) into the sunroof drive cables.
(2) Install screws holding drive motor to bracket.
(3) Connect wire harness to drive motor.
(4) Install headlining.
SUNROOF GLASS PANEL
REMOVAL
(1) Position sunroof sunshade (4) in full rearward
position.
(2) Remove six glass attachment screws.
(3) Push glass panel upward from underside until
glass panel clears the roof panel.
(4) Lift glass panel from vehicle.
INSTALLATION
(1) Position glass panel (4) in opening in vehicle
roof.
(2) Install, but do not tighten, glass attachment
screws.
(3) With the aid of a helper, hold the glass panel in
position and tighten glass attachment screws.
(4) Verify the correct glass height. Refer to Glass
Height Adjustment procedure in this section.
SUNROOF GUIDE AND MECHANISM ASSEMBLY
REMOVAL
(1) Remove sunroof glass panel (4). Refer to proce-
dure in this section.
(2) Remove front locator (7 or 8).
(3) Disengage cable from mechanism (9).
(4) Remove screws holding sunroof guide (5) and
mechanism (9) assembly to sunroof module.
(5) Lift assembly from module.
(6) Rotate assembly to disengage wind deflector
(13) from assembly.
INSTALLATION
(1) Engage wind deflector (13) into guide (5) and
mechanism (9) assembly.
(2) Position assembly onto module and install
screws holding assembly to sunroof module.
(3) Engage drive cable to mechanism.
(4) Install front locator (7 or 8 ). It may ease
installation to move sunroof mechanism slightly rear-
ward.
(5) Install sunroof glass panel. Refer to procedure
found in this section.
SUNROOF MODULE
REMOVAL
(1) Remove headlining.
(2) Remove fasteners attaching sunroof module to
vehicle roof and support braces.
(3) With the aid of a helper, separate sunroof mod-
ule from roof.
(4) Remove sunroof module from vehicle.
INSTALLATION
(1) With the aid of a helper, position sunroof mod-
ule in vehicle.
(2) Install fasteners holding sunroof module to
vehicle roof.
(3) Tighten all fasteners, starting from the front
and working rearward and then the motor bracket.
(4) Adjust glass panel for flushness to roof. Refer
to glass adjustment procedure in this section.
(5) Install headlining.
(6) Verify correct operation.
SUNROOF SUNSHADE
REMOVAL
(1) Remove sunroof glass panel (4). Refer to proce-
dure found in this section.
(2) Slide sunshade (11) to full forward position.
(3) Disengage slide blocks on one side of sunshade
from sunshade guide (6).
(4) Lift and pull sunshade out of opposite sun-
shade guide.
INSTALLATION
(1) Place sunshade with cloth side down and
install one side's slide blocks into the track on the
sunshade guide (6).
(2) Slide the other side's slide blocks to fully
inward position and insert them into the sunshade
guide (6).
(3) Verify that all four slide blocks are fully
engaged in the sunshade guide (6).
(4) Slide sunshade (11) fully rearward.
(5) Install sunroof glass panel (4). Refer to proce-
dure found in this section.
SUNROOF WIND DEFLECTOR
REMOVAL
(1) Open sunroof to full open position.
(2) Pull one end of wind deflector flap out of the
wind deflector beam (13).
(3) Release corner piece locking tab and separate
corner piece from wind deflector beam.
(4) Rotate corner piece outboard to release tab
from roof flange.
23 - 50 BODYPL
REMOVAL AND INSTALLATION (Continued)

MAXIMUM HEATER OUTPUT: TEST AND
ACTION
Engine coolant is provided to the heater system by
two 16 mm (5/8 inch inside diameter) heater hoses.
With engine idling at normal running temperature,
set the control to maximum heat, floor, and high
blower setting. Using a test thermometer, check the
air temperature coming from the floor outlets, refer
to Temperature Reference Table.
If the floor outlet air temperature is insufficient,
refer to Group 7, Cooling Systems for specifications.
Both heater hoses should be HOT to the touch (cool-
ant return hose should be slightly cooler than the
supply hose). If coolant return hose is much cooler
than the supply hose, locate and repair engine cool-
ant flow obstruction in heater system.
POSSIBLE LOCATIONS OR CAUSE OF
OBSTRUCTED COOLANT FLOW
(1) Pinched or kinked heater hoses.
(2) Improper heater hose routing.
(3) Plugged heater hoses or supply and return
ports at cooling system connections, refer to Group 7,
Cooling System.(4) Plugged heater core.
(5) Air locked heater core.
(6) If coolant flow is verified and outlet tempera-
ture is insufficient, a mechanical problem may exist.
POSSIBLE LOCATION OR CAUSE OF
INSUFFICIENT HEAT
(1) Obstructed cowl air intake.
(2) Obstructed heater system outlets.
(3) Blend-air door not functioning properly.
TEMPERATURE CONTROL
If temperature cannot be adjusted with the TEMP
lever on the control panel, the following could require
service:
(1) Blend-air door binding.
(2) Faulty blend-air door cable.
(3) Improper engine coolant temperature.
(4) Faulty Instrument Panel Control.
LOW PRESSURE CUT-OFF SWITCH
The work area must not be below 21ÉC (70ÉF) to
test the compressor clutch circuit.
(1) With gear selector in park or neutral and park
brake set, start engine and allow to idle.
(2) Raise hood and disconnect low pressure cut off
switch connector boot.
(3) Using a suitable jumper wire, jump across the
terminals inside wire connector boot.
(4) If the compressor clutch does not engage, the
cycling clutch switch, wiring, relay, or fuse can be
defective. Refer to Group 8W, Wiring Diagrams.
(5) If clutch engages, connect manifold gauge set.
Read low pressure gauge. At pressure above 97 kPa
(14 psi) and above, low pressure out off switch will
complete the clutch circuit. If the low pressure gauge
reads below 140 kPa (20 psi), the system is low on
refrigerant charge or empty due to a leak. Refer to
Service±Procedures, System Leak Checking in this
section.
(6) Install connector boot on switch and repeat
Step 3. If the clutch does not engage, replace the low
pressure cut off switch.
SYSTEM CHARGE LEVEL TEST
The procedure below should be used to check
and/or fill the refrigerant charge in the air condition-
ing system.
Fig. 11 Evaporator Probe Harness Connector
TEMPERATURE REFERENCE TABLE
Ambient Temp.Minimum
FloorOutlet
Temp.
Celsius Fahrenheit Celsius Fahrenheit
15.5É 60É 62.2É 144É
21.1É 70É 63.8É 147É
26.6É 80É 65.5É 150É
32.2É 90É 67.2É 153É
PLHEATING AND AIR CONDITIONING 24 - 11
DIAGNOSIS AND TESTING (Continued)