DODGE NEON 2000 Service Repair Manual

(3) Disengage clips attaching trim to lower quarter
panel.
(4) Remove seat belt from slot in trim panel.
(5) Remove lower quarter trim from vehicle (Fig.
66).
INSTALLATION
(1) Position lower quarter trim panel to vehicle.
(2) Install seat belt to slot in trim panel.
(3) Align locating pins on backside of trim panel to
mating holes in inner quarter panel.
(4) Press clips on trim panel into slots in inner
quarter panel.
(5) Install rear seat back and cushion.
(6) Install upper quarter trim panel.
FLOOR CONSOLE
REMOVAL
(1) Fully apply parking brake.
(2) Remove screw cover plugs over screws just
rearward of cup holders.
(3) Remove screws in cup holders attaching con-
sole to floor bracket.
(4) Open console storage compartment lid, if so
equipped.
(5) Remove screw cover plugs over screws near
rear of console.
(6) Remove screws attaching console to floor
bracket.
(7) Remove shift lever knob, if vehicle is equipped
with a manual transmission.
(8) Lift console upward over gear selector and park
brake handle.
(9) Remove console from vehicle.
INSTALLATION
(1) Place floor console into position in vehicle.
(2) Install screws attaching console to floor brack-
ets.
(3) Install screw cover plugs.
(4) Install shift lever knob, if vehicle is equipped
with a manual transmission.
(5) Release parking brake.
FRONT SEAT BELT BUCKLE
CAUTION: Front seat belt assemblies must be
replaced after a collision.
REMOVAL
(1) Remove bolt attaching seat belt buckle from
seat anchor.
(2) Remove seat belt buckle from seat.
INSTALLATION
(1) Place seat belt buckle in position on seat
anchor.
(2) Install bolt attaching seat belt buckle to seat
anchor. Tighten seat belt anchor bolt to 40 N´m (30
ft. lbs.) torque.
FRONT SEAT BELT RETRACTOR
CAUTION: Front seat belt assemblies must be
replaced after a collision.
REMOVAL
(1) Remove B-pillar trim.
(2) Remove bolt attaching seat belt retractor to
B-pillar (Fig. 68).
(3) Remove seat belt retractor from vehicle.
INSTALLATION
(1) Install seat belt retractor into vehicle.
(2) Install bolt attaching seat belt retractor to
B-pillar. Tighten seat belt anchor bolt to 40 N´m (30
ft. lbs.) torque.
(3) Install B-pillar trim.
FRONT SHOULDER BELT ADJUSTER
CAUTION: Front seat belt assemblies must be
replaced after a collision.
REMOVAL
(1) Remove B-pillar trim (Fig. 68).
Fig. 67 Floor Console
1 ± FLOOR CONSOLE WITH ARMREST
2 ± ATTACHING SCREWS
23 - 54 BODYPL
REMOVAL AND INSTALLATION (Continued)

(2) Remove the two bolts attaching shoulder belt
adjuster to B-pillar (Fig. 69).
(3) Remove shoulder belt adjuster from vehicle.
INSTALLATION
CAUTION: Front seat belt adjuster must be in the
lowest position when Installing adjuster knob.
(1) Place into position the shoulder belt adjuster.
(2) Install bolts attaching shoulder belt adjuster to
B-pillar. Tighten all seat belt bolts to 40 N´m (30 ft.
lbs.) torque.
(3) Install B-pillar trim.
REAR SEAT BELT BUCKLE
REMOVAL
(1) Remove rear seat cushion.
(2) Remove rear seat belt buckle bolt (Fig. 70).
(3) Remove rear seat belt buckle from vehicle.
INSTALLATION
(1) Install rear seat belt buckle. Tighten the seat
belt nut to 40 N´m (30 ft. lbs.) torque.(2) Install rear seat cushion.
REAR SEAT BELT RETRACTOR
REMOVAL
(1) Remove rear seat cushion and back.
(2) Remove seat belt bezel from parcel shelf cover.
Fig. 68 Front Seat Belt Retractor
1 ± FRONT SEAT BELT ADJUSTER
2 ± UPPER B-PILLAR TRIM PANEL
3 ± ADJUSTER BUTTON
4 ± TURNING LOOP
5 ± SEAT BELT
6 ± SEAT BELT RETRACTOR
7 ± ANCHOR BOLT
8 ± LOWER B-PILLAR TRIM PANEL
Fig. 69 Front Shoulder Belt Adjuster
1 ± FRONT SHOULDER BELT ADJUSTER
2 ± TAB IS ON BOTTOM
Fig. 70 Rear Seat Belt Buckle
1 ± REAR SEAT CUSHION
2 ± CUSHION ATTACHING RETAINER
PLBODY 23 - 55
REMOVAL AND INSTALLATION (Continued)

(3) Remove rear seat closure panel silencer pad as
necessary to gain access to retractor.
(4) Remove bolt attaching seat belt lower anchor to
floor.
(5) Remove bolt attaching retractor to rear seat
closure panel (Fig. 71).
(6) Push seat belt bezel and buckle stab through
access hole in parcel shelf.
(7) From in trunk compartment, remove rear seat
belt retractor from vehicle.
INSTALLATION
(1) Position rear seat belt retractor in trunk com-
partment.
(2) Push seat belt bezel and buckle stab through
access hole in rear shelf trim panel.
(3) Install bolt attaching retractor to rear seat clo-
sure panel. Tighten the seat belt bolt to 40 N´m (30
ft. lbs.) torque.
(4) Install bolt attaching seat belt lower anchor to
floor. Tighten the seat belt bolt to 40 N´m (30 ft. lbs.)
torque.
(5) Install rear seat closure panel silencer pad.
(6) Install seat belt bezel to the rear shelf trim
panel.
(7) Install rear seat cushion and back.
CARPET
REMOVAL
For removal of the carpet, the carpet will need to
be cut under the instrument panel.
(1) Remove front seats.
(2) Remove rear seat cushion.
(3) Remove bolts attaching front seat belt lower
anchors to floor (Fig. 72).(4) Remove door sill trim covers.
(5) Remove cowl trim covers.
(6) Remove center floor console.
(7) Remove decklid 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
The new carpet must be cut for installation. The
area is mark on the reverse side of the carpet. The
location is in front of the tunnel area.
(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 decklid release assist handle.
(6) Install center floor console.
(7) Install cowl trim covers.
(8) Install door sill trim covers.
(9) Install bolts attaching front seat belt lower
anchors to floor. Tighten all seat belts to 40 N´m (30
ft. lbs.) torque.
(10) Install rear seat cushion.
(11) Install front seats.
SUN VISOR
All vehicles with driver and passenger side airbags
must have a colored coded five Bullet point airbag
Fig. 71 Rear Seat Belt Retractor
1 ± REAR RIGHT OUTER SEAT BELT
2 ± SEAT BELT RETRACTOR
Fig. 72 Carpet
1 ± FLOOR CARPET
2 ± TRUNK REAR END PANEL
23 - 56 BODYPL
REMOVAL AND INSTALLATION (Continued)

warning 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 attaching 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
(1) Place sun visor in position.
(2) If equipped, connect wire connector from body
harness.
(3) Install screws attaching sun visor to header.
(4) Install sun visor into center support.
HEADLINER
REMOVAL
(1) Remove screws attaching sun visors to roof
header panel.
(2) Disconnect wire connector from lighted vanity
mirror, if so equipped.
(3) Remove sun visors from vehicle.
(4) Remove A-pillar trim covers.
(5) Remove B-pillar trim panels.
(6) Remove (upper) quarter panel trim panels.
(7) Remove assist handle, if so equipped.
(8) Remove sun visor hooks.
(9) Remove coat hooks, if so equipped.
(10) Remove three push in fasteners at rear of
headliner.
(11) Disengage dome lamp wire connector, at rear
of headliner.
(12) Remove push in fastener attaching wiring to
C-pillar.
(13) Remove headliner through door opening (Fig.
73).
INSTALLATION
(1) Position headliner in vehicle.
(2) Install sun visor hooks, if so equipped.
(3) Install coat hooks, if so equipped.
(4) Install three push in fastener at rear of head-
liner.
(5) Install assist handles, if so equipped.
(6) Install push in fastener attaching headliner
wiring to C-pillar.
(7) Connect dome lamp wire connector, at rear of
headliner.
(8) Install (upper) quarter panel trim panel.
(9) Install B-pillar trim panels.
(10) Install A-pillar trim covers.(11) Install sun visors, lighted vanity mirror wire
connector, if so equipped, and screws attaching sun
visors to roof header panel.
INSIDE REAR VIEW MIRROR
REMOVAL
(1) Loosen the mirror base set screw (Fig. 74).
(2) Slide the mirror base upward and off the
bracket.
INSTALLATION
(1) Position the mirror base at the bracket and
slide it downward onto the support bracket.
(2) Tighten the setscrew 1 N´m (15 in. lbs.) torque.
REAR SHELF TRIM PANEL
REMOVAL
(1) Remove quarter trim panels as necessary.
(2) Remove rear seat cushion and back.
(3) Disengage seat belt bezels from rear shelf trim
panel.
(4) Remove rear seat shoulder belt from the shelf
by sliding belt through the slot.
(5) Remove rear shelf trim panel from vehicle.
INSTALLATION
(1) Place into position rear shelf trim panel.
(2) Slide the rear seat shoulder belt through the
slot in the rear shelf trim panel.
(3) Engage seat belt bezels to rear shelf trim
panel.
Fig. 73 Headliner
1 ± HEADLINER TO REAR HEADER FASTENERS
2 ± HEADLINER
3 ± VISORS
PLBODY 23 - 57
REMOVAL AND INSTALLATION (Continued)

(4) Install rear seat cushion and back.
(5) Install quarter trim.
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 attaching body vent to trunk
well.
(3) Remove body vent from vehicle (Fig. 76).
INSTALLATION
(1) Place body vent in vehicle.
(2) From behind rear bumper fascia below quarter
panel, engage clips attaching body vent to trunk well.
(3) Lower vehicle.
ADJUSTMENTS
FRONT DOOR LATCH ADJUSTMENT
(1) Insert a hex-wrench through the elongated hole
in the door end frame near the latch striker opening.
(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 LATCH ADJUSTMENT
(1) Insert a hex-wrench through the elongated hole
in the door end frame near the latch striker opening.
(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.
Fig. 74 Rear View Mirror
1 ± WINDSHIELD
2 ± MIRROR
3 ± LIGHTED MIRROR CONNECTOR
Fig. 75 Rear Shelf Trim Panel
1 ± REAR SHELF PANEL
2 ± SLOT
3 ± REAR SHELF MOLDING
Fig. 76 Body Vent
1 ± BODY VENT
2 ± TRUNK WELL SIDE PANEL
23 - 58 BODYPL
REMOVAL AND INSTALLATION (Continued)

SPECIFICATIONS
BODY LUBRICATION
LUBRICATION REQUIREMENTS
Body mechanisms and linkages should be
inspected, cleaned, and lubricated, as required, to
maintain ease of operation and to provide protection
against rust and wear. When performing other
underhood services, the hood latch release mecha-
nism and safety catch should be inspected, cleaned,
and lubricated. During the winter season, external
door lock cylinders should be lubricated to assure
proper operation when exposed to water and ice.
Prior to the application of any lubricant, the parts
concerned should be wiped clean to remove dust and
grit. If necessary, a suitable solvent can be used to
clean the item to be lubricated. After lubricating a
component, any excess oil or grease should be
removed.
LUBRICANT APPLICATION
DOOR LOCK CYLINDERS
(1) Apply a small amount of lubricant directly into
the lock cylinder.
(2) Apply a small amount of lubricant to the key.
(3) Insert key into lock cylinder and cycle the
mechanism from the locked to the unlocked position.
NOTE: Do not add more lubricant.
(4) Cycle the lock cylinder mechanism several
times to allow the lubricant to flow throughout the
cylinder.
(5) Wipe all lubricant from exterior of lock cylinder
and key.
ALL OTHER BODY MECHANISMS
(1) Clean component as described above.(2) Apply specified lubricant to all pivoting and
sliding contact areas of component.
LUBRICANT USAGE
ENGINE OIL
²Decklid Hinges
MOPARTSPRAY WHITE LUBE OR EQUIVALENT
²Ash Receiver
²Fuel Filler Door Remote Control Latch Mecha-
nism
²Parking Brake Mechanism
²Sliding Seat Tracks
²Decklid Latch
MOPARTMULTIPURPOSE GREASE OR
EQUIVALENT
²All Other Hood Mechanisms
MOPARTLOCK CYLINDER LUBRICANT OR
EQUIVALENT
²Door Lock Cylinders
²Decklid Lock Cylinder
SPECIAL TOOLS
BODY
STICK, TRIM C 4755
PLBODY 23 - 59

SPECIFICATIONS
TABLE OF CONTENTS
page page
SPECIFICATIONS
BODY LUBRICATION SPECIFICATIONS........60
BODY GAP AND FLUSH MEASUREMENTS.....61
BODY OPENING DIMENSION...............62BODY SEALING LOCATIONS................64
STRUCTURAL ADHESIVE LOCATIONS........74
TORQUE SPECIFICATIONS.................76
WELD LOCATIONS.......................77
SPECIFICATIONS
BODY LUBRICATION SPECIFICATIONS
LUBRICATION REQUIREMENTS
Body mechanisms and linkages should be
inspected, cleaned, and lubricated, as required, to
maintain ease of operation and to provide protection
against rust and wear. When performing other under
hood services, the hood latch release mechanism and
safety catch should be inspected, cleaned, and lubri-
cated. During the winter season, external door lock
cylinders should be lubricated to assure proper oper-
ation when exposed to water and ice.
Prior to the application of any lubricant, the parts
concerned should be wiped clean to remove dust and
grit. If necessary, a suitable solvent can be used to
clean the item to be lubricated. After lubricating a
component, any excess oil or grease should be
removed.
LUBRICANT APPLICATION
DOOR LOCK CYLINDERS
(1) Apply a small amount of lubricant directly into
the lock cylinder.
(2) Apply a small amount of lubricant to the key.
(3) Insert key into lock cylinder and cycle the
mechanism from the locked to the unlocked position.
NOTE: Do not add more lubricant.
(4) Cycle the lock cylinder mechanism several
times to allow the lubricant to flow throughout the
cylinder.
(5) Wipe all lubricant from exterior of lock cylinder
and key.ALL OTHER BODY MECHANISMS
(1) Clean component as described above.
(2) Apply specified lubricant to all pivoting and
sliding contact areas of component.
LUBRICANT USAGE
ENGINE OIL
²Door Hinges ± Hinge Pin and Pivot Contact
Areas
²Hood Hinges ± Pivot Points
²Liftgate Hinges
²Decklid Hinges
MOPARTSPRAY WHITE CUBE OR EQUIVALENT
²Door Check Straps
²Liftgate Latches
²Liftgate Prop Pivots
²Ash Receiver
²Fuel Filler Door Remote Control Latch Mecha-
nism
²Parking Brake Mechanism
²Sliding Seat Tracks
²Decklid Latch
MOPARTMultipurpose GREASE OR EQUIVALENT
²All Other Hood Mechanisms
MOPARTLOCK CYLINDER LUBRICANT OR
EQUIVALENT
²Door Lock Cylinders
²Decklid Lock Cylinder
23 - 60 BODYPL

BODY GAP AND FLUSH MEASUREMENTS
BODY GAP AND FLUSH
LOCATION GAP FLUSH
A Hood to Fender 4.061.0 // 1.061.0
B Hood to Fender (Fore & Aft) Flush w/in61.5 N/A
C Front Door to Fender 5.061.0 // 1.061.0
D Rear Door to Front Door 5.061.0 // 1.061.0
E Fuel Filler Door to Quarter Panel 3.060.75 conc.60.5 0.560.5
F Fascia to Hood Parallel // w/in 2.0 N/A
G Front & Rear Door to Roof 5.061.5 // 1.0 0.061.5 // 1.0
H Deck Lid to Quarter Panel 4.0 1.5 // 1.0 1.061.0 // 1.0
I Tail Lamp to Applique & Deck Lid 4.061.5 // 1.0 1.061.0 // 1.0
J Rear Door to Quarter Panel 4.061.0 // 1.0 0.061.0 // 1.0
K Front & Rear Door to Sill 5.061.5 // 1.5 6.461.5 / 1.5
NOTE: ALL MEASUREMENTS ARE IN mm
PLBODY 23 - 61
SPECIFICATIONS (Continued)

BODY OPENING DIMENSION
DOOR AND WINDSHIELD OPENINGS
23 - 62 BODYPL
SPECIFICATIONS (Continued)

REAR WINDOW AND TRUNK OPENINGS
PLBODY 23 - 63
SPECIFICATIONS (Continued)