height DODGE NEON 1999 Service Owner's Manual

(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)

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

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)

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)

(5) Rotate corner piece to a vertical position and
pull it up through hole in guide (5).
(6) Repeat for other corner piece.
INSTALLATION
(1) Hold corner piece vertically and push tab down
through hole in guide (5).
(2) Rotate corner piece inward and place tab under
roof flange.
(3) Connect corner piece to wind deflector beam
(13).
(4) Install wind deflector flap into wind deflector
beam.
(5) Repeat for other corner piece.
ADJUSTMENTS
SUNROOF GLASS HEIGHT ADJUSTMENT
FLUSHNESS
(1) Position sunshade in full rearward position.
(2) To adjust front of glass;
(a) Loosen front and middle glass attachment
screws
(b) Adjust front of sunroof glass panel so that
the corners are flush to 1.0 mm below the top sur-
face of the roof panel.(c) Tighten all glass attachment screws.
(3) To adjust rear of glass;
(a) Loosen rear and middle glass attachment
screws
(b) Adjust rear of sunroof glass panel so that the
corners are flush to61.0 mm off the top surface of
the roof panel.
(c) Tighten all glass attachment screws.
VENT HEIGHT
(1) Cycle the sunroof module to vent position using
the drive motor.
(2) Check glass height in tilt using the appropriate
measuring tool.
(3) If the vent height is greater than 35 mm, using
switch slowly set to correct height.
(4) After setting correct height, remove drive
motor.
(5) With the motor removed, use the switch to set
tilt by operating the gear to the full closed position.
(6) Using tilt switch only, operate the motor until
it comes to a full stop at tilt position.
(7) Install drive motor and verify correct operation.
PLBODY 23 - 51
REMOVAL AND INSTALLATION (Continued)

DIGIT 5
Market Code
²C = Canada
²B = International
²M = Mexico
²U = United States
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehicle Identification Number²Refer to Vehicle Identification Number (VIN)
paragraph for proper breakdown of VIN code.
IF TWO BODY CODE PLATES ARE REQUIRED
The last code shown on either plate will be fol-
lowed by END. When two plates are required, the
last code space on the first plate will indicate (CTD)
When a second plate is required, the first four
spaces of each line will not be used due to overlap of
the plates.
STANDARD BODY DIMENSIONS
INTERIOR DIMENSIONS
CARBODY
STYLEHEAD ROOM LEG ROOM SHOULDER ROOM HIP ROOM
FRONT REAR FRONT REAR FRONT REAR FRONT REAR
PL PL-421005 mm 928 mm 1080 mm 891 mm 1333 mm 1329 mm 1290 mm 1286 mm
39.6 in. 36.5 in. 42.5 in. 35.1 in. 52.5 in. 52.3 in. 50.8 in. 50.6 in.
PL PL-221005 mm 928 mm 1080 mm 891 mm 1321 mm 1391 mm 1277 mm 1369 mm
39.6 in. 36.5 in. 42.5 in. 35.1 in. 52.0 in. 54.7 in. 50.3 in. 53.9 in.
EXTERIOR DIMENSIONS
CARBODY
STYLEWHEEL
BASEFRONT
TRACKREAR
TRACKOVERALL
LENGTHOVERALL
WIDTHOVERALL
HEIGHT
mm/in. mm/in. mm/in. mm/in. mm/in. mm/in.
PL PL-42 2642/104 1458/57.4 1458/57.4 4364/171.8 1708/67.2 1395/54.9
PL PL-22 2642/104 1458/57.4 1458/57.4 4364/171.8 1711/67.4 1395/54.9
4 INTRODUCTIONPL
GENERAL INFORMATION (Continued)