torque DODGE NEON 2000 Service Repair Manual

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)

(3) Remove hood latch striker from vehicle.
INSTALLATION
(1) Position hood latch striker on vehicle.
(2) Install bolts attaching hood latch striker to
hood. Tighten bolts to 13.5 N´m (10 ft. lbs.) torque.
(3) Align hood latch striker to engage smoothly
into hood latch.(4) Verify hood operation and alignment. Adjust as
necessary.
(5) Tighten attaching bolts to 13.5 N´m (10 ft. lbs.)
torque.
HOOD RELEASE CABLE
REMOVAL
(1) Disconnect remote hood release cable from
hood latch.
(2) Remove left front cowl trim panel.
(3) Remove screws attaching hood release handle
to cowl panel (Fig. 19).
(4) Disconnect rubber grommet from dash panel
behind instrument panel.
(5) Pull release cable through hole in dash panel.
(6) Remove cable and handle from vehicle.
INSTALLATION
(1) Assemble cable and handle onto vehicle.
(2) Push release cable through hole in dash panel.
(3) Connect rubber grommet into dash panel.
(4) Install screws attaching hood release handle to
cowl panel.
(5) Install left front cowl trim panel.
(6) Connect remote hood release cable to hood
latch.
(7) Close hood and verify operation.
Fig. 18 Hood Latch
1 ± HOOD LATCH RELEASE CABLE
2 ± HOOD PROP ROD3 ± HOOD SECURITY ALARM
4 ± HOOD LATCH
Fig. 17 Grille
1 ± GRILLE
PLBODY 23 - 25
REMOVAL AND INSTALLATION (Continued)

(3) Engage clips on trim panel into slots in door
sill.
(4) Engage clips on trim panel onto door opening
flange.
(5) Press downward on trim panel to fully engage
all clips.
SIDE COWL TRIM
REMOVAL
(1) Disengage clips attaching cowl trim to cowl
side panel.
(2) Remove cowl trim from vehicle (Fig. 63).
INSTALLATION
(1) Position cowl trim panel to inner cowl panel.
(2) Align locating pins on backside of cowl trim
panel to mating holes in inner cowl panel.
(3) Push clips on trim panel into slots in inner
cowl panel.
B-PILLAR TRIM
REMOVAL
(1) Remove bolt attaching lower seat belt anchor to
floor pan kick-up (Fig. 64).
(2) Remove shoulder belt height control knob.
(3) Remove bolt attaching turning loop to belt
adjuster (Fig. 65).
(4) Remove access cover from B-pillar trim.
(5) Disengage clips attaching trim to B-pillar.
(6) Feed seat belt turning loop and seat belt
through trim panel.
(7) Remove B-pillar trim from vehicle.
INSTALLATION
NOTE: Tighten all seat belt bolts to 40 N´m (40 ft.
lbs.) torque.
(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.
Fig. 61 A-pillar Trim
1 ± WINDSHIELD A-PILLAR
2 ± CLIPS
3 ± A-PILLAR TRIM
Fig. 62 Door Sill Trim
1 ± FRONT DOOR SILL
2 ± REAR DOOR SILL
3 ± SILL TRIM
Fig. 63 Side Cowl Trim
1 ± DOOR OPENING
2 ± COWL
3 ± SILL
4 ± COWL TRIM
23 - 52 BODYPL
REMOVAL AND INSTALLATION (Continued)

(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)

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

TORQUE SPECIFICATIONS
BODY COMPONENTS
DESCRIPTION TORQUE
All seat belt anchor bolts..... 40N´m(30ft.lbs.)
All seat belt anchor nuts...... 40N´m(30ft.lbs.)
All seat belt retractor bolts.... 40N´m(30ft.lbs.)
Decklid latch striker......... 22N´m(16ft.lbs.)
Front seat track to floor pan bolts . . 55 N´m (40 ft.
lbs.)
Front seat inboard pivot bolt . . . 40 N´m (30 ft. lbs.)
Front seat recliner to seat cushion frame . . 12 N´m
(9 ft. lbs.)
Front seat track to cushion frame bolt . . 12 N´m (9
ft. lbs.)
Front seat back............. 40N´m(30ft.lbs.)DESCRIPTION TORQUE
Front seat back recliner to seat back . 12 N´m (9 ft.
lbs.)
Front door hinge to hinge pillar bolt . 28 N´m (21 ft.
lbs.)
Front door hinge to door nuts and bolt . 28 N´m (21
ft. lbs.)
Front door latch striker....... 28N´m(20ft.lbs.)
Hood latch striker.........13.5 N´m (10 ft. lbs.)
Rear door glass to regulator bolt . . 11 N´m (105 in.
lbs.)
Rear door hinge to B-pillar bolt . 28 N´m (20 ft. lbs.)
Rear door hinge to door bolt . . . 28 N´m (20 ft. lbs.)
Rear door latch striker....... 28N´m(20ft.lbs.)
Rear seat back and seat belt buckle anchor nut . 57
N´m (42 ft. lbs.)
RAIL TO REAR FLOOR PAN
23 - 76 BODYPL
SPECIFICATIONS (Continued)