DODGE NEON 2000 Service Repair Manual

STATIONARY GLASS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
SAFETY PRECAUTIONS....................4
REMOVAL AND INSTALLATION
WINDSHIELD.............................4REAR WINDOW...........................6
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
PINCH WELD (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.
RECOMMENDED TOOLS AND ADHESIVE
POWER KNIFE
²FeintPower Cutout Knife
²EqualizertMagnum, Interior Auto Glass Cut
Out Knife
ADHESIVE, PRIMER AND CLEANER
The following urethane adhesive systems are OEM
certified and conform to the FMVSS 212 windshield
retention standard and the FMVSS 216 roof crush
standard.
WINDSHIELD REMOVAL ± EXTERIOR METHOD
(1) Remove inside rear view mirror.
(2) Remove windshield wiper arms.
(3) Remove cowl cover.
23 - 4 BODYPL

(4) Place protective covers over instrument panel
and hood.
(5) Remove windshield A-pillar 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) Remove 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) Remove replacement windshield from wind-
shield opening.
(4) 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. 3).
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN WINDSHIELD BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(5) Clean inside of windshield with ammonia based
glass cleaner and lint-free cloth.
(6) Apply molding to Top of windshield.
(7) 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.
(8) Apply Glass Primer 25 mm (1 in.) wide around
perimeter of windshield. Allow at least three minutes
drying time.
(9) Using a razor knife, remove as much original
urethane as possible. Do not damage paint on wind-
shield fence.
Fig. 1 Windshield Header and Outside Molding
1 ± WINDSHIELD HEADER MOLDING
2 ± A-PILLAR OUTSIDE MOLDING
3 ± A-PILLAR
Fig. 2 Cut Urethane Around Windshield
1 ± COLD KNIFE
2 ± WINDSHIELD
PLBODY 23 - 5
REMOVAL AND INSTALLATION (Continued)

(10) Apply pinch weld primer 15 mm (.75 in.) wide
around the windshield fence. Allow at least three
minutes drying time.
(11) Apply a 10 mm (0.4 in.) bead of urethane on
center line of windshield fence.
(12) 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.
(13) 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. 4).
(14) Clean access urethane from exterior with
Mopart, Super Clean or equivalent.
(15) 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.
(16) Install A-pillar moldings.
(17) Install cowl cover and wipers.
(18) Install inside rear view mirror.
(19) After urethane has cured, remove tape strips
and water test windshield to verify repair.
REAR WINDOW
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
Refer to the windshield paragraph of this section
for a description of tools and adhesive systems that
are recommended for use in this procedure.
REAR WINDOW REMOVAL
(1) Remove rear window moldings.
(2) Remove upper quarter trim panel.
(3) Disconnect 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) Remove 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.
5).
(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. 5).
(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.
Fig. 3 Work Surface Set up and Molding Installation
1 ± WINDSHIELD AND MOULDINGS
2 ± URETHANE BEAD AROUND GLASS 7mm (.3 in.) FROM
EDGE
3 ± BLOCKS
23 - 6 BODYPL
REMOVAL AND INSTALLATION (Continued)

Fig. 4 Lower Windshield Into Position
1 ± WINDSHIELD
2 ± WINDSHIELD TO FENCE RETAINER
3 ± SECTION D-D
4 ± SECTION B-B
5 ± SECTION C-C6 ± SECTION A-A (FENCE)
7 ± SECTION A-A (GLASS)
8 ± HIGH VISCOSITY ADHESIVE
9 ± WINDSHIELD FENCE SUPPORT SPACERS
Fig. 5 Rear Window Glass
1 ± 9.5 MM
2 ± REAR WINDOW
3 ± SECTION F-F4 ± SECTION E-E
5±3MM
6 ± 12.7 MM
PLBODY 23 - 7
REMOVAL AND INSTALLATION (Continued)

SEATS
TABLE OF CONTENTS
page page
REMOVAL AND INSTALLATION
FRONT SEAT.............................8
FRONT SEAT BACK........................8
FRONT SEAT BACK COVER.................9FRONT SEAT CUSHION COVER..............9
FRONT SEAT CUSHION....................9
REAR SEAT BACK........................10
REAR SEAT CUSHION.....................11
REMOVAL AND INSTALLATION
FRONT SEAT
REMOVAL
(1) Move seat to forward position.
(2) Remove bolts attaching rear of seat track to
floor.
(3) Move seat to rearward position.
(4) Remove bolts attaching front of seat track to
floor crossmember (Fig. 1).
(5) Remove seat from vehicle.
INSTALLATION
(1) Move seat to mid-position andverifythat both
seat tracks are locked into same position with eight
teeth behind the latch mechanism.
(2) Move seat into position in vehicle. Do not use
the head restraint, side shield, recliner handle, or the
adjuster lift bar to move the seat.(3) Ensure that the locating tabs on the front
mounting feet are installed through the slits in the
carpet and into the openings in the floor pan cross-
member.
(4) Install and tighten front inboard bolt attaching
seat track to floor crossmember.
(5) Install front outboard bolt attaching seat track
to floor crossmember. Tighten front seat bolt to 55
N´m (40 ft. lbs.) torque.
(6) Install rear seat track attaching bolts to floor.
Tighten rear seat bolts outboard first then inboard to
55 N´m (40 ft. lbs.) torque.
FRONT SEAT BACK
REMOVAL
(1) Remove seat from vehicle.
(2) Remove seat cushion side shields.
(3) Remove bolts attaching recliner to seat back
cushion frame (Fig. 2).
(4) Remove inboard pivot bolt (Fig. 3).
(5) Disconnect any electrical connectors to the seat
back, if equipped.
(6) Remove seat back from seat cushion.
Fig. 1 Front Seat
1 ± SEAT
2 ± SEAT BELT BOLT
Fig. 2 Recliner Attaching Bolt
1 ± RECLINER BOLT
23 - 8 BODYPL

INSTALLATION
(1) Position seat back on cushion.
(2) Connect electrical connectors to the seat back,
if equipped.
(3) Install inboard pivot bolt. Tighten bolt to 40
N´m (30 ft. lbs.) torque.
(4) Install bolts attaching recliner to seat cushion
frame. Tighten bolts to 12 N´m (9 ft. lbs.) torque.
(5) Install seat cushion side shields.
(6) Install seat in vehicle.
FRONT SEAT BACK COVER
REMOVAL
(1) Remove seat from vehicle.
(2) Remove head restraint.
(3) Remove front seat back.
(4) Disengage the J-strap retainer.
(5) Roll cover upward to hog rings. Cut hog rings
to free cover (Fig. 4).
(6) Roll cover to top of seat back and remove head
restraint sleeve guides.
(7) Remove cover from seat back.
INSTALLATION
NOTE: Do not reuse the recliner assembly attach-
ing bolts.
(1) Position cover at the top of seat back.
(2) Carefully roll cover down to the area that hog
rings are to be installed.
(3) Install hog rings.
(4) Roll cover downward.
(5) Engage the J-strap retainer
(6) Install new head restraint sleeve guides.(7) Install seat back to seat cushion. Tighten bolts
to 40 N´m (30 ft. lbs.) torque.
(8) Install seat in vehicle.
(9) Install head restraint.
(10) Check seat back and headrest operation.
FRONT SEAT CUSHION COVER
REMOVAL
(1) Remove seat from vehicle.
(2) Remove front seat cushion side shields.
(3) Remove seat back.
(4) Remove track and recliner assembly.
(5) Disengage J-strap attaching seat cover from
the seat cushion frame.
(6) Pull cover off to the hog rings.
(7) Cut hog rings attaching seat cover to seat cush-
ion pad.
(8) Remove seat cushion cover from seat cushion.
INSTALLATION
(1) Position seat cover on cushion.
(2) Align seat cover with cushion alignment inden-
tations.
(3) Install hog rings.
(4) Engage J-strap attaching seat cover to front of
seat cushion frame.
(5) Install track and recliner assembly. Tighten
front track to pan bolts to 12 N´m (9 ft. lbs.) torque.
(6) Install seat back.
(7) Install front seat cushion side shields.
(8) Install seat in vehicle.
FRONT SEAT CUSHION
REMOVAL
(1) Remove seat from vehicle.
(2) Remove front seat cushion side shield.
Fig. 3 Remove Seat Back
1 ± RECLINER BOLT HOLE
2 ± SEAT BACK BOLT HOLE
3 ± J-STRAP RETAINER
Fig. 4 Front Seat Back Hog Rings
1 ± SEAT COVER
2 ± HOG RINGS
3 ± CUSHION
PLBODY 23 - 9
REMOVAL AND INSTALLATION (Continued)

(3) Remove seat back.
(4) Remove track and recliner assembly.
(5) Remove seat cushion (Fig. 5).
INSTALLATION
(1) Connect seat cushion heater element connector,
if equipped.
(2) Install track and recliner assembly. Tighten
bolts to 12 N´m (9 ft. lbs.) torque.
(3) Install seat back. Tighten bolts to 40 N´m (30
ft. lbs.) torque.
(4) Install cushion side shields.
(5) Install seat in vehicle.
REAR SEAT BACK
REMOVAL
(1) Remove rear seat cushion.
(2) Remove bolts attaching rear seat back and seat
belts to floor.
(3) Push rear seat back upward to disengage hooks
at top of seat back (Fig. 6).
(4) Remove 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 attaching 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.
Fig. 5 Front Seat Cushion
1 ± FRONT SEAT CUSHION
Fig. 6 Rear Seat Back
1 ± REAR SEAT BACK
2 ± REAR OUTER RIGHT SEAT BELT
3 ± REAR INNER LEFT SEAT BELT
4 ± REAR INNER RIGHT SEAT BELT
23 - 10 BODYPL
REMOVAL AND INSTALLATION (Continued)

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) Remove rear seat cushion from vehicle (Fig. 7).
INSTALLATION
(1) Place rear seat cushion in position under bot-
tom of seat back.
(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.
Fig. 7 Rear Seat Cushion
1 ± REAR SEAT CUSHION
2 ± CUSHION ATTACHING RETAINER
PLBODY 23 - 11
REMOVAL AND INSTALLATION (Continued)

BODY COMPONENTS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
GRILLE................................13
HOOD.................................13
FRONT DOOR...........................14
SPLASH SHIELD.........................16
DIAGNOSIS AND TESTING
WATER LEAKS..........................18
WIND NOISE............................19
SERVICE PROCEDURES
HEAT STAKING..........................19
PLASTIC BODY PANEL REPAIR..............19
REMOVAL AND INSTALLATION
GRILLE................................23
HOOD LATCH...........................24
HOOD LATCH STRIKER....................24
HOOD RELEASE CABLE...................25
HOOD.................................26
HOOD SILENCER........................26
HOOD HINGE...........................26
COWL COVER...........................27
FRONT WHEELHOUSE SPLASH SHIELD......28
FENDER...............................28
EXTERIOR BADGEING ATTACHED WITH
DOUBLE SIDED FOAM TAPE..............28
EXTERIOR BADGEING/TAPE STRIPES
ATTACHED WITH ADHESIVES.............28
FRONT/REAR DOOR WINDOW CRANK........29
FRONT DOOR TRIM......................30
FRONT DOOR WATER DAM................30
DOOR OUTER BELT WEATHERSTRIP.........30
FRONT/REAR DOOR INNER BELT
WEATHERSTRIP........................32
FRONT DOOR GLASS RUN WEATHERSTRIP . . . 32
FRONT DOOR OUTSIDE HANDLE............33
DOOR LOCK CYLINDER...................33
FRONT DOOR LATCH.....................33
FRONT DOOR LATCH STRIKER.............34
FRONT VERTICAL GUIDE BAR..............34
FRONT DOOR GLASS.....................36
FRONT DOOR CHECK STRAP..............36
FRONT DOOR...........................36
FRONT DOOR HINGE.....................38
FRONT/REAR DOOR APPLIQUE.............38
SIDE VIEW MIRROR......................39
SIDE VIEW MIRROR TRIM BEZEL............39
DOOR UPPER SECONDARY WEATHERSTRIP . . 39
SILL SECONDARY WEATHERSTRIP..........40
REAR DOOR TRIM.......................40REAR DOOR WATER DAM.................40
REAR DOOR OUTSIDE HANDLE.............40
REAR DOOR LATCH......................41
REAR DOOR LATCH STRIKER..............43
REAR DOOR GLASS......................43
REAR DOOR WINDOW REGULATOR.........43
REAR DOOR GLASS RUN WEATHERSTRIP....43
REAR DOOR CHECK STRAP................45
REAR DOOR............................45
REAR DOOR HINGE......................45
FUEL FILL DOOR.........................46
DECKLID LATCH.........................47
DECKLID...............................47
DECKLID LIFT SPRINGS...................47
DECKLID LOCK CYLINDER.................48
DECKLID LATCH STRIKER.................48
DECKLID OPENING WEATHERSTRIP.........49
TRUNK CARPET.........................49
DECKLID COVER.........................50
ROOF RAIL WEATHERSTRIP................50
ROOF RAIL WEATHERSTRIP RETAINER
CHANNEL.............................50
B-PILLAR WEATHERSTRIP CHANNEL.........51
A-PILLAR TRIM..........................51
DOOR SILL TRIM.........................51
SIDE COWL TRIM........................52
B-PILLAR TRIM..........................52
UPPER QUARTER TRIM...................53
LOWER QUARTER TRIM...................53
FLOOR CONSOLE........................54
FRONT SEAT BELT BUCKLE................54
FRONT SEAT BELT RETRACTOR............54
FRONT SHOULDER BELT ADJUSTER.........54
REAR SEAT BELT BUCKLE.................55
REAR SEAT BELT RETRACTOR.............55
CARPET...............................56
SUN VISOR.............................56
HEADLINER.............................57
INSIDE REAR VIEW MIRROR...............57
REAR SHELF TRIM PANEL.................57
BODY VENT.............................58
ADJUSTMENTS
FRONT DOOR LATCH ADJUSTMENT.........58
REAR DOOR LATCH ADJUSTMENT..........58
SPECIFICATIONS
BODY LUBRICATION......................59
SPECIAL TOOLS
BODY.................................59
23 - 12 BODYPL

DESCRIPTION AND OPERATION
GRILLE
HOOD
1 ± GRILLE
HOOD HARDWARE
1 ± HOOD LATCH RELEASE CABLE
2 ± HOOD PROP ROD3 ± HOOD SECURITY ALARM
4 ± HOOD LATCH
HOOD SILENCER
1 ± HOOD
2 ± HOOD SILENCER
PLBODY 23 - 13