tra DODGE NEON 2000 Service Repair Manual

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)

(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)

(7) Install pull cup support bracket, water shield,
and door trim panel.
Fig. 48 Door Glass Run Weatherstrip
1 ± REAR DOOR GLASS RUN WEATHERSTRIP
2 ± REAR DOOR
3 ± DOOR TRIM PANEL4 ± SPACER
5 ± WINDOW REGULATOR HANDLE
6 ± DOOR CHECK STRAP
Fig. 47 Rear Door Glass
1 ± REAR DOOR GLASS
2 ± REAR DOOR
3 ± LATCH STRIKER4 ± SPACER
5 ± REAR WINDOW MANUAL REGULATOR
6 ± WINDOW TO REGULATOR FASTENERS
23 - 44 BODYPL
REMOVAL AND INSTALLATION (Continued)

REAR DOOR CHECK STRAP
REMOVAL
(1) Remove door trim panel.
(2) Remove bolts attaching check strap to hinge
pillar.
(3) Remove check strap seal from door end frame.
(4) Remove bolts attaching check strap to door end
frame (Fig. 49).
(5) Remove check strap from vehicle.
INSTALLATION
CAUTION: Do not close door before adjusting the
door latch. Door may fail to open.
(1) Position door check strap on vehicle.
(2) Install check strap attaching bolts to the door
end frame.
(3) Install check strap seal. If seal is damaged or
worn replace seal.
(4) Install check strap attaching bolts to the hinge
pillar.
(5) Install door trim panel.
REAR DOOR
REMOVAL
(1) Open door and support on a suitable lifting
device.(2) Disconnect the wire connector at the hinge pil-
lar.
(3) Remove bolts attaching door check strap to
B-pillar.
(4) Remove bolts attaching lower hinge to door
(Fig. 50).
(5) Remove bolts attaching upper hinge to door.
INSTALLATION
(1) Apply MopartMultimileage Grease to the
inside of the door hinge bushings.
(2) Install bolts to the upper hinge to door.
(3) Install bolts to the lower hinge to door.
(4) Connect the wire connector at the B-pillar.
(5) Remove lifting device.
(6) Adjust door as necessary.
REAR DOOR HINGE
NOTE: If both hinges on one door are to be
replaced, remove and install one hinge completely
prior to beginning the second hinge.
REMOVAL
(1) Open and support door on a suitable lifting
device.
(2) Remove bolts attaching door check strap to
lower B-pillar for greater access, if necessary.
(3) Mark position of hinge on both the door end
frame and lower B-pillar to ease installation.
Fig. 49 Rear Door Check Strap
1 ± REAR DOOR GLASS RUN WEATHERSTRIP
2 ± REAR DOOR
3 ± DOOR TRIM PANEL4 ± SPACER
5 ± WINDOW REGULATOR HANDLE
6 ± DOOR CHECK STRAP
PLBODY 23 - 45
REMOVAL AND INSTALLATION (Continued)

(4) Remove bolts attaching hinge to door end
frame (Fig. 50).
(5) Remove bolts attaching hinge to lower B-pillar.
(6) Remove door hinge from vehicle.
INSTALLATION
NOTE: Do not grease door hinges.
(1) If necessary, paint new door hinge prior to
installation.
(2) Position door hinge on vehicle.
(3) Loosely install bolts attaching hinge to lower
B-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 B-pillar, if removed previously.
(7) Verify door fit and operation. Adjust door hinge
for proper door alignment, if necessary.
FUEL FILL DOOR
REMOVAL
(1) Open the fuel filler door.
(2) Remove the screws attaching the door to the
quarter panel (Fig. 51).(3) Remove the door from the panel.
INSTALLATION
(1) Position the fuel filler door on the quarter
panel with the screw holes aligned.
(2) Install the screws attaching the fuel filler door
to the quarter panel.
Fig. 50 Rear Door
1 ± UPPER HINGE
2 ± REAR DOOR
3 ± CHECK STRAP4 ± LOWER HINGE
5 ± BODY ASSEMBLY
Fig. 51 Fuel Filler Door
1 ± BODY ASSEMBLY
2 ± FUEL FILLER DOOR
23 - 46 BODYPL
REMOVAL AND INSTALLATION (Continued)

(6) Install bolt attaching turning loop to belt
adjuster.
(7) Move adjuster in to the lowest position.
(8) Install shoulder belt height control knob.
(9) Install bolt attaching lower seat belt anchor to
floor pan kick-up.
UPPER QUARTER TRIM
REMOVAL
(1) Disengage clips attaching trim to upper quar-
ter panel (Fig. 66).
(2) Remove upper trim panel from vehicle.
INSTALLATION
(1) Check to ensure that electric rear window wir-
ing is positioned correctly in the roof channel pro-
vided.
(2) Position trim panel in vehicle.
(3) Align locating pins on backside of trim panel to
mating holes in upper quarter panel.
(4) Push clips on trim panel into slots in upper
quarter panel.
LOWER QUARTER TRIM
REMOVAL
(1) Remove upper quarter trim panel.
(2) Remove rear seat cushion and back.
Fig. 64 B-pillar Trim
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. 65 Turning Loop to Belt Adjuster
1 ± FRONT SHOULDER BELT ADJUSTER
2 ± TAB IS ON BOTTOM
Fig. 66 Upper Quarter Trim
1 ± UPPER QUARTER TRIM PANEL
2 ± LOWER QUARTER TRIM PANEL
3 ± SEAT BELT
PLBODY 23 - 53
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)

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