2000 DODGE NEON Service Repair Manual

(2) Install the five screws holding cowl panel to
cowl at base of windshield opening.
(3) Push the hood to cowl seal over the forward
flange of the cowl cover and cowl plenum.
(4) Install windshield wiper arms, refer to Group
8K, Windshield Wiper and Washer Systems, for
proper procedures.
FRONT WHEELHOUSE SPLASH SHIELD
REMOVAL
(1) Hoist and support vehicle on safety stands.
(2) Remove front wheel.
(3) Remove push-in fasteners attaching splash
shield to frame rail forward of suspension (Fig. 24).
(4) Remove push in fasteners attaching splash
shield to frame rail rearward of suspension.
(5) Remove screws attaching wheelhouse splash
shield to front fender.
(6) Remove splash shield from vehicle.
INSTALLATION
(1) Place splash shield in position on vehicle.
(2) Install screws attaching wheelhouse splash
shield to front fender.
(3) Install push in fasteners attaching splash
shield to frame rail rearward of suspension.
(4) Install push in fasteners attaching splash
shield to frame rail forward of suspension.
(5) Install front wheel.
(6) Lower vehicle.
FENDER
REMOVAL
(1) Remove headlamp housing.
(2) Right side of vehicle remove pulley splash
shield.(3) Remove inner splash shield.
(4) Remove fender to fascia nuts.
(5) Remove fender bolt to lower rocker panel.
(6) Remove fender bolt to lower cowl.
(7) Pull fascia away from fender.
(8) Remove bolts attaching fender to upper rail.
(9) Remove fender from vehicle (Fig. 25).
INSTALLATION
(1) Place fender in position on vehicle.
(2) Start the center upper rail bolt.
(3) From inside engine compartment, install all
the bolts attaching fender to upper rail and tighten.
(4) Install lower cowl panel bolt to fender.
(5) Install rocker panel bolt to fender.
(6) Place fascia into position.
(7) Install fender to fascia nuts.
(8) Install inner splash shield.
(9) Install right side pulley splash shield.
(10) Install headlamp assembly.
(11) Check fender for flush and gap.
EXTERIOR BADGEING ATTACHED WITH
DOUBLE SIDED FOAM TAPE
REMOVAL
(1) Mark reference points before removing.
(2) Using a heat gun gently apply heat in a circu-
lar motion to loosen the adhesive bond.
(3) Using a nonmetallic prying device, such as a
plastic or wood trim stick gently pry up at corners
and remove.
(4) Clean off all traces of adhesive or double sided
tape from the panel with a general purpose adhesive
remover.
INSTALLATION
(1) Clean panel surface with isopropy alcohol.
(2) Align badgeing to reference points.
(3) Install and press securely to full adhesive con-
tact
(4) Clean away any reference points.
EXTERIOR BADGEING/TAPE STRIPES
ATTACHED WITH ADHESIVES
REMOVAL
(1) Mark reference points before removing.
(2) Using a heat gun gently apply heat in a circu-
lar motion to loosen the adhesive bond.
(3) With your fingernail lift up and peel away
badgeing /tape from panel, using a heat gun as you
go.
(4) Clean off all traces of adhesive from the pan-
el(s) with a general purpose adhesive remover.
Fig. 23 Cowl Cover
1 ± COWL TOP SCREEN
23 - 28 BODYPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Clean panel surface with isopropy alcohol.
(2) Remove paper carrier and align badgeing/tape
to reference points or adjacent panel.
(3) Install and press securely, using a plastic
spreader to eliminate all air bubbles.
(4) Remove top protective carrier.
(5) Clean away any reference points.
FRONT/REAR DOOR WINDOW CRANK
REMOVAL
(1) Open door.
(2) Slide a window crank removal tool behind the
window crank to release crank handle lock clip (Fig.
26).
(3) Remove handle from regulator shaft.
Fig. 25 Fender
1 ± FENDER
Fig. 24 Front Wheelhouse Splash Shield
1 ± PUSH IN PLUG
2 ± FRONT FASCIA
3 ± PULLEY SPLASH SHIELD4 ± FRONT FASCIA
5 ± PULLEY SPLASH SHIELD
6 ± FRONT FENDER SPLASH SHIELD
PLBODY 23 - 29
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Place the lock clip on the window crank.
(2) Place window crank on regulator shaft with the
window in the down position.
(3) Orientate the window regulator crank handle
appropriately at the 10 o'clock position and the left
handle at the 2 o'clock position.
(4) Push the handle in to the lock position on the
regulator shaft.
FRONT DOOR TRIM
REMOVAL
(1) Release door latch and open door.
(2) Lower door glass.
(3) Remove window regulator crank, if so equipped
(Fig. 26).
(4) Remove screw from inside arm rest pull cup
(Fig. 27).
(5) Remove screw from behind inside latch release
handle.
(6) Disengage push-in fasteners attaching trim to
door panel around perimeter of trim panel.
(7) Tilt trim panel outward to clear locator pins on
backside of trim panel.
(8) Disconnect trim panel from retainer channel in
inner belt weatherstrip at top of door by lifting while
gently jiggling.
(9) Move trim panel away from door and disengage
clip attaching latch rod to handle.
(10) Remove latch rod from handle.
CAUTION: Do not allow door trim panel to hang by
the wire connector or wiring.(11) Disconnect wire connector from power door
lock switch, mirror switch, and power window switch
if so equipped.
(12) 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 near door.
(3) Connect wire connector into power door lock
switch, mirror switch, and power window switch, if
so equipped.
(4) Insert latch rod into handle and engage clip.
(5) Install trim panel into retainer channel at top
of door and push down to seat.
(6) Locate door trim panel to inner door panel by
aligning locating pins on backside of trim panel to
mating holes in inner door panel.
(7) Install push in fasteners to hold trim to door
panel around perimeter of trim panel.
(8) Install screw inside latch release handle.
(9) Install screw inside arm rest pull cup.
(10) With the window in the down position, orien-
tate the window regulator crank handle appropri-
ately. Install the right handle at the 10 o'clock
position and the left handle at the 2 O'clock position,
if so equipped.
FRONT 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. 28).
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.
DOOR OUTER BELT WEATHERSTRIP
REMOVAL
(1) Open door glass.
Fig. 26 Window Crank
1 ± WINDOW CRANK REMOVAL TOOL
2 ± WINDOW CRANK
23 - 30 BODYPL
REMOVAL AND INSTALLATION (Continued)

(2) Pull upward at rear end of outer belt weather-
strip.
(3) Remove outer belt weatherstrip from vehicle
(Fig. 29).INSTALLATION
(1) Starting at leading edge of door, press weather-
strip onto door.
(2) Operate window and check for interference
Fig. 27 Front Door Trim
1 ± FRONT DOOR
2 ± LINK AND SLEEVES
3 ± INNER REMOTE HANDLE
4 ± POWER DOOR LOCK SWITCH5 ± DOOR TRIM SCREWS
6 ± FRONT DOOR TRIM PANEL
7 ± INSIDE DOOR HANDLE
Fig. 28 Water Dam
1 ± U NUTS
2 ± LINK AND SLEEVES
3 ± FRONT DOOR4 ± WATER DAM
5 ± TRIM ATTACHING BRACKET
PLBODY 23 - 31
REMOVAL AND INSTALLATION (Continued)

FRONT/REAR DOOR INNER BELT
WEATHERSTRIP
REMOVAL
(1) Remove door trim panel.
(2) Remove weatherstrip from door. Use a rubber
mallet and a block of wood, tap upward at each clip
holding the molding to the door (Fig. 30).
INSTALLATION
(1) Push down on weatherstrip to engage channel
to door panel.
(2) Install door trim panel.
FRONT DOOR GLASS RUN WEATHERSTRIP
REMOVAL
(1) Remove flag cover, door trim panel, water dam
as necessary.
(2) Remove door glass.
(3) Loosen side view mirror, as necessary.
(4) Remove weatherstrip fasteners.
(5) Pull weatherstrip from lower front channel
above door latch.
(6) Pull run weatherstrip from window frame
channel (Fig. 31).
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.
(7) Tighten side view mirror.
(8) Install pull cup support bracket, water shield,
door trim panel and flag trim.
Fig. 29 Door Outer Belt Weatherstrip
1 ± REAR DOOR OUTER BELT WEATHERSTRIP
2 ± FRONT DOOR OUTER BELT WEATHERSTRIP3 ± DOOR MOLDING
4 ± OUTER BELT WEATHERSTRIP
Fig. 30 Front/Rear Door Inner Belt Weatherstrip
1 ± REAR DOOR
2 ± FRONT DOOR
3 ± INNER BELT WEATHERSTRIP
23 - 32 BODYPL
REMOVAL AND INSTALLATION (Continued)

FRONT DOOR OUTSIDE HANDLE
REMOVAL
(1) Remove door trim panel and water dam.
(2) Close door glass.
(3) Disconnect lock and latch rods from door latch.
(4) Remove nut attaching door handle retainer to
outer door panel (Fig. 32).
(5) Remove retainer from back of door handle.
(6) Remove door handle from vehicle.
INSTALLATION
(1) Position door handle into door and install
retainer at back of handle.
(2) Install nut attaching door handle retainer to
outer door panel.
(3) Connect lock and latch rods to door latch.
(4) Install door trim panel and water dam.
DOOR LOCK CYLINDER
REMOVAL
(1) Remove door trim panel and water dam.
(2) Close door glass.
(3) Disconnect door lock rod from latch.
(4) Remove clip attaching lock cylinder to door
handle.
(5) Pull lock cylinder from door handle (Fig. 33).
INSTALLATION
(1) Push lock cylinder into door handle.
(2) Install clip attaching lock cylinder to door han-
dle.
(3) Connect door lock rod from latch.
(4) Install door trim panel and water dam.
FRONT DOOR LATCH
REMOVAL
(1) Remove door trim panel and water shield.
(2) Close door glass.
(3) Disconnect lock and latch rods from door latch
(Fig. 34).
(4) Disengage wire connector from power door lock
motor, if equipped.
(5) Remove screws holding latch to door end
frame.
(6) Remove door latch from vehicle.
INSTALLATION
CAUTION: Do not close door before adjusting the
door latch. Door may fail to open.
(1) Position door latch inside door and install
screws holding latch to door end frame.
(2) Engage wire connector into power door lock
motor, if so equipped.
Fig. 31 Door Glass Run Weatherstrip
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 - 33
REMOVAL AND INSTALLATION (Continued)

(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)