trunk DODGE NEON 1999 Service Owner's Manual

FRAME AND BUMPERS
CONTENTS
page page
BUMPERS............................... 1FRAMES................................ 3
BUMPERS
INDEX
page page
REMOVAL AND INSTALLATION
FRONT BUMPER FASCIA.................. 1
FRONT BUMPER REINFORCEMENT.......... 1REAR BUMPER FASCIA................... 1
REAR BUMPER REINFORCEMENT........... 2
REMOVAL AND INSTALLATION
FRONT BUMPER FASCIA
REMOVAL
(1) Remove nuts holding front bumper fascia
bracket to bottom of fender forward of front wheels.
(2) Remove screws holding front fascia to inner
wheelhouse.
(3) Remove bolts holding fascia to bumper rein-
forcement forward of radiator (Fig. 1).
(4) Remove bolts holding fascia to bottom of
bumper reinforcement.
(5) Separate fascia from vehicle.
INSTALLATION
(1) Position fascia on vehicle.
(2) Install bolts holding fascia to bottom of bumper
reinforcement.
(3) Install bolts holding fascia to bumper reinforce-
ment forward of radiator (Fig. 1).
(4) Install screws holding front fascia to inner
wheelhouse.
(5) Install radiator grille, refer to Group 23, Body
for proper procedures.
FRONT BUMPER REINFORCEMENT
REMOVAL
(1) Remove front fascia.
(2) Support bumper reinforcement on a suitable
lifting device.
(3) Remove nuts holding reinforcement to radiator
closure panel (Fig. 2).
(4) Separate bumper reinforcement from vehicle.
INSTALLATION
Reverse the preceding operation.
REAR BUMPER FASCIA
REMOVAL
(1) Release trunk lock and open trunk lid.
(2) Remove bolts holding fascia to tail closure
panel.
(3) Remove push±in fasteners holding fascia to
bottom of rear bumper reinforcement (Fig. 3).
Fig. 1 Front Bumper Fascia
PLFRAME AND BUMPERS 13 - 1

TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Front Bumper Reinforcement
Nut.....................156 N´m (115 ft. lbs)
Rear Bumper Reinforcement
Nut.....................156 N´m (115 ft. lbs)
Front Crossmember To Body
Mounting Bolts...........163 N´m (120 ft. lbs)
Fig. 8 Rear Window and Trunk Openings
13 - 10 FRAME AND BUMPERSPL
SPECIFICATIONS (Continued)

BODY COMPONENTS
INDEX
page page
DIAGNOSIS AND TESTING
WATER LEAKS.......................... 3
WIND NOISE............................ 4
SERVICE PROCEDURES
HEAT STAKING.......................... 4
REMOVAL AND INSTALLATION
WINDOW REGULATORÐ4 DOOR........... 36
A-PILLAR TRIM.......................... 4
B-PILLAR APPLIQUEÐ2 DOOR.............. 5
B-PILLAR APPLIQUEÐ4 DOOR.............. 5
B-PILLAR TRIMÐ4 DOOR.................. 6
B-PILLAR WEATHERSTRIP CHANNEL......... 6
BODY VENT............................. 6
CARPET............................... 7
CHILD RESTRAINT SEAT BACK............. 8
CHILD SEAT MODULE..................... 8
COWL COVER........................... 7
DOOR HINGE........................... 9
DOOR LOCK CYLINDER.................. 10
DOOR OPENING TRIM WELT.............. 10
DOOR SILL TRIM........................ 10
DOOR................................. 9
FLOOR CONSOLE LATCH................. 11
FLOOR CONSOLE....................... 11
FRONT DOOR CHECK STOP............... 11
FRONT DOOR GLASSÐ2 DOOR............ 12
FRONT DOOR GLASSÐ4 DOOR............ 13
FRONT DOOR INNER BELT WEATHERSTRIP . . 13
FRONT DOOR LATCH STRIKER............ 14
FRONT DOOR LATCH.................... 13
FRONT DOOR OUTER BELT WEATHERSTRIP . 14
FRONT DOOR OUTSIDE HANDLE........... 14
FRONT DOOR TRIM PANEL................ 14
FRONT DOOR WATER SHIELD............. 16
FRONT DOOR WEATHERSTRIP............ 16
FRONT OUTBOARD SEAT BELT............ 17
FRONT SEAT BELT BUCKLE............... 18
FRONT SEAT BELT RETRACTOR........... 18
FRONT SEAT........................... 17
FRONT SHOULDER BELT ADJUSTER........ 18
FRONT VERTICAL GUIDE BAR............. 18
GRILLE............................... 19
HEADLINING........................... 19
HOOD HINGE.......................... 20
HOOD LATCH.......................... 21
HOOD RELEASE CABLE.................. 21
HOOD................................ 20
LOCK BUTTON BELL-CRANK.............. 21
LOWER QUARTER TRIMÐ4 DOOR.......... 22PARCEL SHELF TRIM.................... 22
QUARTER TRIM PANELÐ2 DOOR........... 22
REAR DOOR GLASS..................... 23
REAR DOOR INNER BELT WEATHERSTRIP . . . 23
REAR DOOR INTERLOCK LATCH STRIKER . . . 24
REAR DOOR LATCH STRIKER............. 24
REAR DOOR LATCH..................... 24
REAR DOOR LOCK BELL CRANK........... 24
REAR DOOR OUTER BELT WEATHERSTRIP . . 25
REAR DOOR TRIM....................... 25
REAR DOOR WINDOW REGULATOR........ 25
REAR SEAT BACK....................... 26
REAR SEAT BELT BUCKLE................ 26
REAR SEAT BELT RETRACTOR............ 26
REAR SEAT CUSHION.................... 26
REAR SPOILER......................... 27
REAR VERTICAL GUIDE BAR.............. 27
ROOF APERTURE (RAP) MOLDING.......... 28
ROOF RACK CROSS RAILS............... 28
ROOF RACK........................... 28
ROOF RAIL WEATHER-STRIP FOUR DOOR . . . 29
ROOF RAIL WEATHER-STRIP ± TWO DOOR . . . 29
SIDE COWL TRIM....................... 30
SIDE VIEW MIRROR STANCHION........... 31
SIDE VIEW MIRROR TRIM COVER.......... 31
SIDE VIEW MIRROR..................... 30
SUN VISOR SUPPORT................... 31
SUN VISOR............................ 31
TRUNK CARPET........................ 31
TRUNK LATCH STRIKER.................. 32
TRUNK LATCH.......................... 32
TRUNK LID LIFT SPRINGS................ 33
TRUNK LID............................ 32
TRUNK LOCK CYLINDER................. 33
TRUNK TRIM PANEL..................... 34
TRUNK WEATHERSTRIP.................. 34
UPPER QUARTER TRIMÐ4 DOOR.......... 34
WINDOW INNERBELT STABILIZER.......... 34
WINDOW REGULATORÐ2 DOOR........... 35
ADJUSTMENTS
FRONT DOOR GLASS ADJUSTMENT........ 37
FRONT DOOR LATCH ADJUSTMENT........ 38
REAR DOOR GLASS ADJUSTMENT......... 38
REAR DOOR LATCH ADJUSTMENT.......... 39
SPECIFICATIONS
BODY LUBRICATION SPECIFICATIONS....... 39
SPECIAL TOOLS
BODY................................. 40
23 - 2 BODYPL

B-PILLAR TRIMÐ4 DOOR
REMOVAL
(1) Remove bolt holding lower seat belt anchor to
floor pan kick-up.
(2) Remove shoulder belt height control knob.
(3) Remove bolt holding turning loop to belt
adjuster (Fig. 4).
(4) Remove access cover from B-pillar trim.
(5) Disengage clips holding trim to B-pillar.
(6) Feed seat belt turning loop and seat belt
through trim panel.
(7) Separate B-pillar trim from vehicle.
INSTALLATION
(1) Position B±pillar trim panel near B±pillar.
(2) Feed seat belt turning loop and seat belt
through trim panel.
(3) Align locating pins on backside of trim panel to
mating holes in B±pillar.
(4) Push clips on trim panel into slots in B±pillar.
(5) Install access cover to B-pillar trim.
(6) Install bolt holding turning loop to belt
adjuster.
(7) Install shoulder belt height control knob.
(8) Install bolt holding lower seat belt anchor to
floor pan kick-up.
B-PILLAR WEATHERSTRIP CHANNEL
REMOVAL
(1) Remove B-pillar applique.
(2) Remove push-in fasteners holding weatherstrip
to B-pillar.(3) Pull weatherstrip from B-pillar channels.
(4) Remove screws holding channels to B-pillar
(Fig. 5).
(5) Separate channels from B-pillar.
INSTALLATION
Reverse the preceding operation.
BODY VENT
REMOVAL
(1) Hoist rear end of vehicle and support on safety
stands.
(2) From behind rear bumper fascia below quarter
panel, disengage clips holding body vent to trunk
well.
(3) Separate body vent from vehicle (Fig. 6).
INSTALLATION
Reverse the preceding operation.
Fig. 4 B-pillar Trim
Fig. 5 B-pillar Weatherstrip Channel
Fig. 6 Body Vent
23 - 6 BODYPL
REMOVAL AND INSTALLATION (Continued)

CARPET
REMOVAL
(1) Remove front seats.
(2) Remove rear seat cushion.
(3) Remove bolts holding front seat belt lower
anchors to floor (Fig. 7).
(4) Remove door sill trim covers.
(5) Remove cowl trim covers.
(6) Remove center floor console.
(7) Remove trunk release assist handle.
(8) Remove lower fasteners from B±pillar trim
panel.
(9) Pull carpet from behind trim panel.
(10) Fold carpet in half toward rear seat.
(11) Remove carpet through rear door opening.
INSTALLATION
(1) Install carpet through rear door opening.
(2) Unfold carpet.
(3) Tuck carpet behind trim panel.
(4) Install lower fasteners holding B±pillar trim
panel.
(5) Install trunk release assist handle.
(6) Install center floor console.(7) Install cowl trim covers.
(8) Install door sill trim covers.
(9) Install bolts holding front seat belt lower
anchors to floor.
(10) Install rear seat cushion.
(11) Install front seats.
COWL COVER
REMOVAL
(1) Release hood latch and open hood.
(2) Remove windshield wiper arms, refer to Group
8K, Windshield Wiper and Washer Systems for
proper procedures.
(3) Remove push-in fasteners holding cowl cover to
cowl at base of windshield opening (Fig. 8).
(4) Separate cowl cover from vehicle.
INSTALLATION
(1) Place cowl panel in place on vehicle.
(2) Install push-in fasteners holding cowl panel to
cowl at base of windshield opening.
(3) Install windshield wiper arms, refer to Group
8K, Windshield Wiper and Washer Systems, for
proper procedures.
Fig. 7 CarpetFig. 8 Cowl Cover
PLBODY 23 - 7
REMOVAL AND INSTALLATION (Continued)

CHILD RESTRAINT SEAT BACK
REMOVAL
(1) Remove rear seat cushion.
(2) Open child seat and remove lining.
(3) Remove bolts holding seat back frame to trunk
closure panel through access holes in child seat mod-
ule (Fig. 9).
(4) Remove bolts holding bottom of rear seat back
and seat belts to floor.
(5) Lift seat back upward to disengage retainer
hooks from trunk closure panel.
(6) Separate rear seat back from vehicle.
INSTALLATION
(1) Move child restraint seat back into position in
vehicle.
(2) Push seat back downward to engage hooks into
trunk closure panel.
(3) Install bolts holding bottom of rear seat back
and seat belts to floor.
(4) Install bolts holding seat back frame to trunk
closure panel through access holes in child seat mod-
ule.
(5) Install child seat lining and close child seat.
(6) Install rear seat cushion.
CHILD SEAT MODULE
REMOVAL
(1) Remove rear seat back from vehicle.
(2) Slide lower bolster cushion retainer from chan-
nel on child seat cushion.
(3) Separate lower bolster from seat child seat.
(4) Remove liner from child seat module.(5) Disengage push-in fasteners holding upper bol-
ster to child seat module above shoulder belts.
(6) Remove screws holding top of child seat module
to seat back frame from behind shoulder belts.
(7) Remove screws holding bottom of child seat
module to seat back frame (Fig. 10).
(8) Separate child seat module from seat back.
INSTALLATION
(1) Place child seat module in position on seat
back.
(2) Install screws to hold bottom of child seat mod-
ule to seat back frame.
CAUTION: Do not capture seat belt webbing
between module and seat back frame when install-
ing upper screws.
(3) Install screws to hold top of child seat module
to seat back frame from behind shoulder belts.
(4) Engage push-in fasteners to hold upper bolster
to child seat module above shoulder belts.
(5) Install liner in child seat module.
(6) Place lower bolster in position on seat child
seat.
(7) Slide lower bolster cushion retainer into chan-
nel on child seat cushion.
(8) Install rear seat back in vehicle.
Fig. 9 Child Restraint Seat BackFig. 10 Child Seat Module
23 - 8 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)

(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)