DODGE NEON 2000 Service Repair Manual

(3) Connect latch and lock rods to door latch.
(4) Install door trim panel and water shield.
(5) Adjust door latch using procedure in this sec-
tion.
FRONT DOOR LATCH STRIKER
REMOVAL
(1) Mark outline of door latch striker on B-pillar to
aid installation.(2) Remove screws attaching door latch striker to
B-pillar (Fig. 35).
(3) Remove door latch striker from vehicle.
INSTALLATION
(1) Install door latch striker into the door.
(2) Install screws attaching door latch striker to
B-pillar loosely.
(3) Align door latch striker to outline marks on the
B-pillar
(4) Tighten screws attaching door latch striker to
B-pillar.
(5) Check door alignment and adjust as necessary.
FRONT VERTICAL GUIDE BAR
REMOVAL
(1) Remove door trim panel and water dam.
(2) Remove door speaker, if equipped.
(3) Remove front lift guide.
(4) Remove bolt attaching top of front guide bar to
inner door panel.
(5) Using a Snap-ontflare-nut socket (FRXM10)
and a hex wrench, remove nut attaching bottom of
guide bar to door panel while holding jack screws.
INSTALLATION
(1) Install nut attaching bottom of guide bar to
door panel.
(2) Install bolt attaching top of front guide bar to
inner door panel.
(3) Install front lift guide.
Fig. 32 Front Door Outside Handle
1 ± LOCK TO LATCH LINK & SLEEVE
2 ± OUTSIDE HANDLE TO LATCH
3 ± REAR DOOR4 ± OUTSIDE DOOR HANDLE
5 ± CHILD SAFETY LATCH
6 ± INSIDE DOOR HANDLE LINK & SLEEVE
Fig. 33 Door Lock Cylinder
1 ± OUTSIDE DOOR HANDLE
2 ± LOCK CYLINDER
3 ± RETAINER
23 - 34 BODYPL
REMOVAL AND INSTALLATION (Continued)

(4) Install door speaker, if equipped.
(5) Verify door glass alignment, adjust if necessary.
(6) Install door trim panel and water dam.
Fig. 34 Front Door Latch
1 ± INSIDE LOCK TO LATCH
2 ± OUTSIDE HANDLE TO LATCH
3 ± POWER DOOR LOCK CONNECTOR
4 ± REAR DOOR LATCH5 ± MANUAL
6 ± POWER
7 ± INSIDE DOOR HANDLE TO LATCH
Fig. 35 Front Door Latch Striker
1 ± FRONT DOOR GLASS RUN WEATHERSTRIP
2 ± FRONT DOOR
3 ± B-PILLAR
4 ± SPACER
5 ± DOOR LATCH STRIKER
6 ± WINDOW REGULATOR HANDLE7 ± SPACER
8 ± DOOR TRIM PANEL
9 ± WINDOW REGULATOR
10 ± DOOR CHECK STRAP
11 ± FRONT DOOR GLASS RUN BRACKET WEATHER
PLBODY 23 - 35
REMOVAL AND INSTALLATION (Continued)

FRONT DOOR GLASS
REMOVAL
(1) Remove door trim panel and water dam.
(2) Remove inner door belt weatherstrip.
(3) Loosen window inner belt stabilizer.
(4) Lower door glass to bottom of door to gain
access to attaching bolts.
(5) Remove bolts attaching door glass to window
regulator lift plates (Fig. 36).
(6) Disengage door glass from regulator.
(7) Lift door glass upward out of the opening at
the top of door.
INSTALLATION
(1) Carefully lower door glass through opening in
top of door.
(2) Position door glass into window regulator lift
plates.
(3) Install bolts door glass to lift plates and do not
tighten.
(4) Tighten window inner belt stabilizer.
(5) Raise glass to the full up position and then
tighten the lift plate bolts.
(6) Install inner door belt weatherstrip.
(7) Install door trim panel and water dam.
FRONT DOOR CHECK STRAP
REMOVAL
(1) Remove door trim panel and water dam.(2) Remove bolt attaching check strap to hinge pil-
lar.
(3) Remove door speaker.
(4) Remove glass run.
(5) Remove bolts attaching check strap to door end
frame (Fig. 38).
(6) Remove check strap from vehicle.
INSTALLATION
NOTE: Do not grease check strap.
(1) Position door check on vehicle and install bolts
attaching strap to door end frame.
(2) Install glass run.
(3) Install door speaker, if so equipped.
(4) Install bolt attaching door check strap to hinge
pillar.
(5) Install door trim panel and water dam.
FRONT DOOR
REMOVAL
NOTE: The retaining clips used on the door hinge
pins are not to be reused. Verify availability prior to
proceeding.
(1) Open and support door on a suitable lifting
device.
Fig. 36 Front Door Glass ± Power Window
1 ± FRONT DOOR GLASS
2 ± FRONT DOOR
3 ± POWER WINDOW REGULATOR4 ± POWER WINDOW CONNECTORS
5 ± WINDOW TO REGULATOR FASTENER
23 - 36 BODYPL
REMOVAL AND INSTALLATION (Continued)

(2) Disconnect wire connector at hinge pillar, if
necessary.
(3) Remove bolts attaching door check strap to
hinge pillar.
(4) Remove bolts attaching lower hinge to door.(5) Remove bolts attaching upper hinge to door.
(Fig. 39).
(6) Remove door from vehicle.
Fig. 37 Front Door Glass ± Manual Window
1 ± FRONT DOOR
2 ± FRONT WINDOW MANUAL REGULATOR3 ± WINDOW TO REGULATOR FASTENERS
4 ± FRONT DOOR GLASS
Fig. 38 Front Door Check Strap
1 ± FRONT DOOR GLASS RUN WEATHERSTRIP
2 ± FRONT DOOR
3 ± B-PILLAR
4 ± SPACER
5 ± DOOR LATCH STRIKER
6 ± WINDOW REGULATOR HANDLE7 ± SPACER
8 ± DOOR TRIM PANEL
9 ± WINDOW REGULATOR
10 ± DOOR CHECK STRAP
11 ± FRONT DOOR GLASS RUN BRACKET WEATHER
PLBODY 23 - 37
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Apply MopartMultimileage Grease to inside of
door hinge bushings.
(2) Position door to the hinges on vehicle.
(3) Install bolt into hinge top hole on the right side
or bottom hole left side (smallest hole).
(4) Install bolt into hinge bottom hole on the right
side or top hole left side (slotted hole).
(5) Install bolts attaching door check strap to
hinge pillar.
(6) Connect wire connector at hinge pillar, if nec-
essary.
FRONT DOOR HINGE
REMOVAL
(1) Open and support door on a suitable lifting
device.
(2) Remove bolts attaching door check strap to
lower A-pillar for greater access, if necessary.
(3) Mark position of hinge on both the door end
frame and lower A-pillar to ease installation.
(4) Remove bolts attaching hinge to door end
frame (Fig. 39).
(5) Remove bolts attaching hinge to lower A-pillar.
(6) Remove door hinge from vehicle.
INSTALLATION
CAUTION: When installing a new hinge, make sure
that the head of each hinge pin is fully seated into
the door hinge. Also, remove the plastic shipping
clip and replace it with the correct metal retaining
clip once the hinge pin is seated.
(1) If necessary, paint new door hinge prior to
installation.
(2) Position door hinge on vehicle.
(3) Loosely install bolts attaching hinge to lower
A-pillar.
(4) Loosely install bolts attaching hinge to door
end frame.
(5) Align hinge to marks made previously and
tighten all bolts.
(6) Install bolts attaching door check strap to
lower A-pillar, if removed previously.
(7) Verify door fit and operation. Adjust door hinge
for proper door alignment, if necessary.
FRONT/REAR DOOR APPLIQUE
REMOVAL
(1) Using a fork type prying tool, disengage push
in fasteners attaching applique to door.
(2) Remove applique from door (Fig. 40).
Fig. 39 Front Door
1 ± BODY ASSEMBLY
2 ± UPPER HINGE3 ± FRONT DOOR
4 ± LOWER HINGE
23 - 38 BODYPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Place applique into position on door.
(2) Install fasteners into door applique.
SIDE VIEW MIRROR
REMOVAL
(1) Remove side view mirror bezel or door trim
panel as necessary.
(2) Remove nuts attaching mirror to door inner
panel (Fig. 41).
(3) Manual mirrors snap left side manual remote
from bezel.
(4) Electrical mirrors disconnect.
(5) Remove mirror from vehicle.
INSTALLATION
(1) Position side view mirror on vehicle and install
nuts attaching mirror to door inner panel.
(2) Connect electrical mirror connector.
(3) Install nuts attaching mirror.
(4) Install mirror bezel or door trim panel as nec-
essary.
SIDE VIEW MIRROR TRIM BEZEL
REMOVAL
(1) Disengage clips attaching side view mirror
bezel to stanchion. Left side only with manual mir-
rors (Fig. 41).
(2) Remove mirror bezel from vehicle.
INSTALLATION
(1) Place mirror bezel in position.
(2) Engage clips attaching side view mirror bezel
to stanchion.
DOOR UPPER SECONDARY WEATHERSTRIP
REMOVAL
(1) Using a fork-type prying tool, disengage push
in fasteners attaching door upper secondary weather-
strip to door opening.
(2) Remove weatherstrip from door.
Fig. 40 Front and Rear Door Applique
1 ± FRONT B-PILLAR APPLIQUE
2 ± REAR B-PILLAR APPLIQUE3 ± REAR DOOR SIDE GLASS APPLIQUE
Fig. 41 Side View Mirror
1 ± MIRROR ASSEMBLY
2 ± MIRROR BEZEL
PLBODY 23 - 39
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Position weatherstrip to opening door.
(2) Press door upper secondary weatherstrip fas-
teners into position.
SILL SECONDARY WEATHERSTRIP
REMOVAL
(1) Using a fork-type prying tool, disengage push
in fasteners attaching sill secondary weatherstrip to
door (Fig. 42).
(2) Remove weatherstrip from door.
INSTALLATION
(1) Position weatherstrip to door.
(2) Press sill secondary weatherstrip fasteners into
position.
REAR DOOR TRIM
REMOVAL
(1) Release door latch and open door.
(2) Lower window glass.
(3) Remove window regulator crank.
(4) Remove screw from inside arm rest pull cup.
(5) Remove screw from behind inside latch release
handle (Fig. 43).
(6) Disengage push in fasteners attaching trim to
door panel around perimeter of trim panel.
(7) Disengage push-in metal spring clip holding
trim in sail flag area.
(8) Lift trim panel up off belt weatherstrip.(9) Tilt top of trim panel away from door and dis-
engage clip attaching latch rod to handle.
(10) Remove latch rod from handle.
(11) Remove trim panel from door.
INSTALLATION
(1) Replace any damaged or missing push in fas-
teners from around perimeter of door trim panel.
(2) Place trim panel in position on door.
(3) Insert latch rod into handle and engage clip.
(4) Engage trim panel into retainer channel at top
of door.
(5) Locate door trim panel to inner door panel by
aligning locating pins on backside of trim panel to
mating holes in inner door panel.
(6) Engage push in fasteners attaching trim to
door panel around perimeter of trim panel.
(7) Install screw behind inside latch release han-
dle.
(8) Install screw inside arm rest pull cup.
(9) Install window regulator crank.
REAR DOOR WATER DAM
REMOVAL
(1) Remove door trim panel.
(2) Remove door speaker, if equipped.
(3) Remove door trim pull cup mount bracket.
(4) Disconnect clip attaching lock linkage to lock
button bell-crank.
(5) Peel water dam away from adhesive around
perimeter of inner door panel (Fig. 44).
INSTALLATION
(1) Insure that enough adhesive remains to
securely retain the water dam. Replace as necessary.
(2) Place the water dam into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(3) Engage clip attaching lock linkage to lock but-
ton bell-crank.
(4) Install door trim pull cup mount bracket.
(5) Install door speaker, if equipped.
(6) Install door trim panel.
REAR DOOR OUTSIDE HANDLE
REMOVAL
(1) Remove door trim panel.
(2) Close door glass.
(3) Disengage clips attaching linkage rods to door
handle.
(4) Remove nuts attaching outside handle to door
(Fig. 45).
(5) Remove outside handle.
Fig. 42 Front/Rear Sill Secondary Weatherstrip
1 ± FRONT DOOR
2 ± REAR DOOR
3 ± SILL SECONDARY WEATHERSTRIP
23 - 40 BODYPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Position door outside handle in opening.
(2) Tighten attaching nuts.
(3) Connect linkage rods to latch.
(4) Connect lock and latch rods to door handle.
(5) Install door trim panel.
REAR DOOR LATCH
REMOVAL
(1) Remove door trim panel.
(2) Close door glass.
(3) Loosen lower rear run channel.
Fig. 43 Rear Door Trim
1 ± REAR DOOR
2 ± LINK AND SLEEVES
3 ± DOOR TRIM SCREWS
4 ± POWER DOOR LOCK SWITCH5 ± LINK AND SLEEVES
6 ± REAR DOOR TRIM PANEL
7 ± INSIDE DOOR HANDLE
8 ± WATER DAM
Fig. 44 Water Dam
1 ± LINK AND SLEEVES
2 ± REAR DOOR
3 ± WATER DAM4 ± TRIM ATTACHING BRACKET
5 ± REAR DOOR TYPICAL
PLBODY 23 - 41
REMOVAL AND INSTALLATION (Continued)

(4) Disconnect clips attaching linkage rods to door
latch.
(5) Remove linkage rods from latch (Fig. 46).
(6) Remove screws attaching latch to door end
frame
(7) Remove door latch from vehicle.INSTALLATION
CAUTION: Do not close door before adjusting the
door latch. Door may fail to open.
Fig. 45 Rear Door Outside Handle
1 ± LOCK TO LATCH LINK & SLEEVE
2 ± OUTSIDE HANDLE TO LATCH
3 ± REAR DOOR4 ± OUTSIDE DOOR HANDLE
5 ± CHILD SAFETY LATCH
6 ± INSIDE DOOR HANDLE LINK & SLEEVE
Fig. 46 Rear Door Latch
1 ± INSIDE LOCK TO LATCH
2 ± OUTSIDE HANDLE TO LATCH
3 ± POWER DOOR LOCK CONNECTOR
4 ± REAR DOOR LATCH5 ± MANUAL
6 ± POWER
7 ± INSIDE DOOR HANDLE TO LATCH
23 - 42 BODYPL
REMOVAL AND INSTALLATION (Continued)

(1) Position door latch on vehicle and install
screws attaching latch to door end frame.
(2) Connect linkage rods to latch.
(3) Connect lock and latch rods to door latch.
(4) Tighten lower rear run channel.
(5) Install door trim panel.
REAR DOOR LATCH STRIKER
REMOVAL
(1) Mark outline of door latch striker on B-pillar to
aid installation.
(2) Remove screws attaching door latch striker to
B-pillar (Fig. 47).
(3) Remove door latch striker from vehicle.
INSTALLATION
(1) Install door latch striker from vehicle.
(2) Install screws attaching door latch striker to
B-pillar.
(3) Align marked outline of door latch striker on
B-pillar to aid installation.
REAR DOOR GLASS
REMOVAL
(1) Remove door trim panel and inner belt weath-
erstrip.
(2) Lower the window to 50 mm (2 ins.) from bot-
tom of travel.
(3) Loosen bolts attaching rear lower run channel
to inner door panel (Fig. 47).
(4) Remove rear run channel from door.
(5) Loosen screws attaching window regulator
channel to glass.
(6) Slide channel rearward to allow screw heads to
pass through key hole slots in channel.
(7) Remove glass from roller channel.
(8) Lift door glass upward out of the opening at
the top of door.
INSTALLATION
(1) Lower door glass through opening in top of
door and into position in the window regulator.
(2) Position door glass onto roller channel.
(3) Slide roller channel forward to allow screw
heads to engage key hole slots in channel.
(4) Tighten screws attaching window regulator
roller channel to glass.
(5) Install inner door belt door trim panel inner
belt weatherstrip.
(6) Operate window and check for interference.
Adjust glass as necessary.
REAR DOOR WINDOW REGULATOR
REMOVAL
(1) Remove door trim panel.
(2) Remove door glass from regulator channel.
(3) Loosen screws attaching window regulator
channel and crank housing to door panel (Fig. 47).
(4) Disengage screw and bolt heads from keyhole
slots in door panel.
(5) Loosen bolts attaching window regulator to
door panel.
(6) Disengage regulator from door panel, and
crank housing.
(7) Slide regulator rearward and rotate forward
end of roller channel through access hole in door
panel,
(8) Remove window regulator from door through
access hole in inner panel.
INSTALLATION
(1) position window regulator and crank housing
on door panel through access hole in door panel.
(2) Tighten bolts attaching window regulator to
door panel.
(3) Engage window regulator bolt heads on chan-
nel to key hole slots in door panel.
(4) Tighten screw attaching window regulator
channel and crank housing.
(5) Position glass to regulator roller channel.
(6) Tighten fasteners attaching door glass to roller
channel.
(7) Install door trim panel.
REAR DOOR GLASS RUN WEATHERSTRIP
REMOVAL
(1) Remove door trim panel, water dam as neces-
sary.
(2) Remove door glass.
(3) Remove weatherstrip fasteners.
(4) Pull weatherstrip from lower front channel
above door latch.
(5) Pull run weatherstrip from window frame
channel (Fig. 48).
INSTALLATION
(1) Clean butyl material from door flange area.
(2) Place door run weatherstrip in position on win-
dow frame channel.
(3) Push door run weatherstrip into window frame
channel.
(4) Push weatherstrip into lower front channel
above door latch.
(5) Install weatherstrip fasteners.
(6) Install door glass.
PLBODY 23 - 43
REMOVAL AND INSTALLATION (Continued)