2000 DODGE NEON height

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Page 794 of 1285

DODGE NEON 2000 Service Repair Manual DESCRIPTION SPECIFICATION
Exhaust 5.906±5.924 mm
(0.2326±0.2333 in.)
Valve Stem to Guide Clearance
Intake 0.048±0.066 mm
(0.0018±0.0025 in.)
Max. Allowable 0.076 mm
(0.003 in.)
Service Limit 0.25

Page 813 of 1285

DODGE NEON 2000 Service Repair Manual (3) Start the two rear crossmember mounting bolts
into the tapping plates mounted in the body. The
right side bolt can be viewed in the mounting bolt
figure (Fig. 5). The left side bolt is located in

(3) Start the two rear crossmember mounting bolts
into the tapping plates mounted in the body. The
right side bolt can be viewed in the mounting bolt
figure (Fig. 5). The left side bolt is located in the
same location on the other side of the vehicle. Next,
install the two front mounting bolts attaching front
suspension crossmember to frame rails of vehicle.
Lightly tighten all four mounting bolts to a approxi-
mately 2 N´m (20 in. lbs.) to hold the front suspen-
sion crossmember in position.
NOTE: When reinstalling the front suspension
crossmember back in the vehicle, it is very impor-
tant that the crossmember be attached to the body
in exactly the same spot as when it was removed.
Otherwise, the vehicle's wheel alignment settings
(caster and camber) will be lost.
(4) Using a soft face hammer, tap the front suspen-
sion crossmember back-and-forth or side-to-side until
it is aligned with the previously scribed positioning
marks on the body of the vehicle (Fig. 6). Once the
front suspension crossmember is correctly positioned,
tighten the rear two crossmember mounting bolts to
a torque of 203 N´m (150 ft. lbs.), then tighten the
front two crossmember mounting bolts to a torque of
142 N´m (105 ft. lbs.).
(5) Tighten the lower control arm front pivot bolts
to a torque of 163 N´m (120 ft. lbs.).
(6) Attach the steering gear to the front suspen-
sion crossmember (Fig. 4). Install the four power
steering gear mounting bolts. Tighten the mounting
bolts to a torque of 61 N´m (45 ft. lbs.).
(7) Remove the wire or cord suspending the power
steering gear to the underbody.
(8) If the vehicle is equipped with a power steering
fluid cooler, install the two screws securing the cooler
to the front suspension crossmember. They are
located behind the cooler.
(9)
Install each ball joint stud into the steering
knuckle aligning the bolt hole in the knuckle boss with
the notch formed in the side of the ball joint stud.
(10) Install a new ball joint stud pinch bolt and
nut (Fig. 2). Tighten the nut to a torque of 95 N´m
(70 ft. lbs.).
(11) Fasten the engine torque strut to the right
forward corner of the front suspension crossmember
using its mounting bolt (Fig. 5). Follow the procedure
described in the ENGINE service manual group to
properly align and tighten the torque strut and it's
mounting bolts.
NOTE: Before installing the stabilizer bar, make
sure the bar is not upside-down. The stabilizer bar
must be installed with the curve on the outboard
ends of the bar facing downward to clear the con-
trol arms once fully installed (Fig. 7).(12)
First, place the stabilizer bar in position on the
front suspension crossmember. The slits in each cush-
ion must point toward the front of the vehicle and sit
directly on top of the raised beads formed into the
stamping on the crossmember. Next, install the cush-
ion retainers, matching the raised beads formed into
the cushion retainers to the grooves formed into the
cushions. Install the cushion retainer bolts, but do not
completely tighten them at this time.
(13) Install both stabilizer bar links back on vehi-
cle (Fig. 1). Start each stabilizer bar link bolt with
bushing from the bottom, through the stabilizer bar,
inner link bushings, lower control arm, and into the
upper retainer/nut and bushing. Do not fully tighten
the link assemblies at this time.
(14) Install the tire and wheel assemblies back on
vehicle. Tighten the wheel mounting nuts to 135 N´m
(100 ft. lbs.) torque.
(15) Lower the vehicle.
NOTE: It may be necessary to put the vehicle on a
platform hoist or alignment rack to gain access to
the stabilizer bar mounting bolts with the vehicle at
curb height.
(16) Tighten each stabilizer bar link by holding the
upper retainer/nut with a wrench and turning the
link bolt. Tighten each link bolt to a torque of 23
N´m (200 in. lbs.).
(17) Tighten the stabilizer bar cushion retainer
bolts to a torque of 34 N´m (300 in. lbs.).
(18) Check the front wheel alignment on the vehi-
cle. Refer to WHEEL ALIGNMENT in the SUSPEN-
SION service manual group.
Fig. 7 Downward Curve
1 ± STABILIZER BAR
2 ± LINK
3 ± DOWNWARD CURVE
4 ± CUSHION RETAINER
13 - 8 FRAME AND BUMPERSPL
REMOVAL AND INSTALLATION (Continued)

Page 902 of 1285

DODGE NEON 2000 Service Repair Manual NOTE: Do not tighten the coupling pinch bolt any-
time the vehicle is not at curb riding height. It may
cause unwanted conditions within the steering col-
umn if the vehicle is suspended in any manner

NOTE: Do not tighten the coupling pinch bolt any-
time the vehicle is not at curb riding height. It may
cause unwanted conditions within the steering col-
umn if the vehicle is suspended in any manner
when the pinch bolt is tightened.
(6) Ensure front wheels of vehicle are positioned
STRAIGHT-AHEAD, then align and attach the steer-
ing column upper coupling to the lower coupling.
Install the coupling pinch bolt (Fig. 3). Tighten the
pinch bolt nut to a torque of 28 N´m (250 in. lbs.).
(7) Install the coupling pinch bolt retainer pin.
(8) Remove the steering wheel holding clamp.
REMOVAL AND INSTALLATION
SERVICE WARNINGS AND CAUTIONS
WARNING: BEFORE BEGINNING ANY SERVICE
PROCEDURES THAT INVOLVES REMOVING THE
AIR BAG. REMOVE AND ISOLATE THE NEGATIVE
(-) BATTERY CABLE (GROUND) FROM THE VEHI-
CLE BATTERY. THIS IS THE ONLY SURE WAY TO
DISABLE THE AIR BAG SYSTEM. FAILURE TO DO
THIS COULD RESULT IN ACCIDENTAL AIR BAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
WARNING: THE AIR BAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIR BAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. FAILURE TO DO SOCOULD RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIR BAG AND POSSIBLE PERSONAL INJURY.
THE FASTENERS, SCREWS, AND BOLTS, ORIGI-
NALLY USED FOR THE AIR BAG COMPONENTS,
HAVE SPECIAL COATINGS AND ARE SPECIFI-
CALLY DESIGNED FOR THE AIR BAG SYSTEM.
THEY MUST NEVER BE REPLACED WITH ANY SUB-
STITUTES. ANYTIME A NEW FASTENER IS
NEEDED, REPLACE WITH THE CORRECT FASTEN-
ERS PROVIDED IN THE SERVICE PACKAGE OR
FASTENERS LISTED IN THE PARTS BOOKS.
BEFORE SERVICING A STEERING COLUMN
EQUIPPED WITH AN AIR BAG, REFER TO GROUP
8M, ELECTRICAL FOR PROPER AND SAFE SER-
VICE PROCEDURES.
WARNING: WHEN HANDLING AN UNDEPLOYED
AIR BAG MODULE DURING SERVICING OF THE
STEERING COLUMN, THE FOLLOWING PRECAU-
TIONS SHOULD BE OBSERVED:
²AT NO TIME SHOULD ANY SOURCE OF ELEC-
TRICITY BE PERMITTED NEAR THE INFLATOR ON
THE BACK OF THE AIR BAG MODULE.
²WHEN CARRYING A LIVE MODULE, THE TRIM
COVER SHOULD BE POINTED AWAY FROM THE
BODY TO MINIMIZE INJURY IF THE MODULE
SHOULD ACCIDENTLY DEPLOY.
²IF THE AIR BAG MODULE IS PLACED ON A
BENCH OR OTHER SURFACE, THE PLASTIC
COVER SHOULD BE FACE-UP TO MINIMIZE MOVE-
MENT, IN CASE OF ACCIDENTAL DEPLOYMENT.
CAUTION: Safety goggles should be worn at all
times when working on steering columns.
CAUTION: Disconnect negative (ground) cable from
the battery, before servicing any column compo-
nent.
CAUTION: Do not attempt to remove the pivot pins
to disassemble the tilting mechanism. Damage will
occur.
STEERING COLUMN
NOTE: Before proceeding with this removal and
installation procedure, review SERVICE WARNINGS
AND CAUTIONS at the beginning of REMOVAL AND
INSTALLATION in this section.
Fig. 5 Lower Coupling Inspection
1 ± FLEX JOINT
2 ± SEAL COLLAR SEALING SURFACE
3 ± TO STEERING COLUMN
4 ± CORRUGAGATED TUBE SECTION
5 ± TO STEERING GEAR
PLSTEERING 19 - 31
DIAGNOSIS AND TESTING (Continued)

Page 907 of 1285

DODGE NEON 2000 Service Repair Manual (g) Install the ignition key cylinder in the steer-
ing column. To do this, first position the key cylin-
der in the ON position (with the key in it) so the
retaining tab can be depressed. Push key cy

(g) Install the ignition key cylinder in the steer-
ing column. To do this, first position the key cylin-
der in the ON position (with the key in it) so the
retaining tab can be depressed. Push key cylinder
into the column ignition cylinder housing until the
retaining tab locks into place (Fig. 16).
NOTE: When installing a tilt column, do not release
the tilt lever from the locked position until after the
column is installed on the instrument panel.
(2) Install the steering column into steering col-
umn access opening in the lower instrument panel.
(3) If the vehicle is equipped with a SKIM, Con-
nect its wiring harness electrical connector (Fig. 15).(4) Connect the wiring harness electrical connec-
tors to the multi-function switch, windshield wiper
switch, and ignition switch (Fig. 14).
(5) Connect the wiring harness electrical connector
to the clockspring (Fig. 13).
(6) Align the slots in the mounting brackets on the
steering column with the studs in the instrument
panel (Fig. 12) Attach the column to the instrument
panel by first installing the two upper mounting nuts
(Do not completely tighten the two upper mounting
nuts at this time). Next, install the two lower mount-
ing nuts. Tighten all four mounting nuts to a torque
of 17 N´m (150 in. lbs.).
(7) If the vehicle is equipped with an automatic
transaxle, connect the automatic transaxle ignition
interlock cable to the steering column by pushing the
end of the cable into the back side of the ignition cyl-
inder housing until it snaps into place (Fig. 11).
(8) Position the steering column shaft in the cor-
rect position for mounting to the lower coupling. To
do this, turn the steering wheel end of the shaft until
the missing spline area on that end of the shaft faces
straight up.
(9) Verify the front wheels of vehicle are in the
STRAIGHT-AHEAD position.
NOTE: Do not tighten the coupling pinch bolt any-
time the vehicle is not at curb riding height. It may
cause unwanted conditions within the steering col-
umn if the vehicle is suspended in any manner
when the pinch bolt is tightened.
(10) Reconnect the steering column lower coupling
to the steering column upper coupling (Fig. 10).
Install the coupling pinch bolt an tighten the pinch
Fig. 18 Multi-function/Wiper Switch Mounting
1 ± MOUNTING SCREWS
2 ± MULTI-FUNCTION/WINDSHIELD WIPER SWITCH ASSEMBLY
Fig. 19 SKIM Mounting
1 ± HALO TRIM RING
2 ± MOUNTING SCREWS
3 ± SKIM
Fig. 20 Ignition Switch Mounting
1 ± MOUNTING SCREW
2 ± IGNITION SWITCH
19 - 36 STEERINGPL
REMOVAL AND INSTALLATION (Continued)

Page 1078 of 1285

DODGE NEON 2000 Service Repair Manual CLEANING AND INSPECTION
CLEANING TIRES
Remove the protective coating on the tires before
delivery of a vehicle. This coating may cause deteri-
oration of the tires.
To remove the protective coating, a

Page 1143 of 1285

DODGE NEON 2000 Service Repair Manual HOOD
REMOVAL
(1) Raise hood to full up position.
(2) Disengage under hood lamp wire connector
from engine compartment wire harness.
(3) Remove hood cover (Fig. 20).
(4) Mark all bolt and hinge attachm

HOOD
REMOVAL
(1) Raise hood to full up position.
(2) Disengage under hood lamp wire connector
from engine compartment wire harness.
(3) Remove hood cover (Fig. 20).
(4) Mark all bolt and hinge attachment locations
with a grease pencil or other suitable device to pro-
vide reference marks for installation. When installing
hood, align all marks and secure bolts. The hood
should be aligned to 4 mm (0.160 in.) gap to the front
fenders and flush across the top surfaces along fend-
ers.
(5) Remove the top bolts attaching hood to hinge
and loosen the bottom bolts until they can be
removed by hand.
(6) With assistance from a helper at the opposite
side of the vehicle to support the hood, remove bot-
tom bolts attaching hood to hinge.
(7) Remove the hood from the vehicle.
INSTALLATION
(1) Place hood in position on vehicle. With assis-
tance from a helper at the opposite side of the vehicle
to support the hood, install bottom bolts to hold hood
to hinge finger tight.
(2) Install top bolts attaching hood to hinge finger
tight.
(3) Position bolts at marks and tighten bolts. The
hood should be aligned to 4 mm (0.160 in.) gap to the
front fenders and flush across the top surfaces along
fenders.(4) Install hood cover.
(5) Engage under hood lamp wire connector to
engine compartment wire harness.
(6) Verify hood operation and alignment.
HOOD SILENCER
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect hood lamp wire connector and
remove hood lamp (Fig. 21).
(3) Remove fasteners attaching hood silencer to
hood.
(4) Remove hood silencer from vehicle.
INSTALLATION
(1) Place hood silencer in position on vehicle.
(2) Install fastener attaching hood silencer to hood.
(3) Install hood lamp and connect wire connector.
(4) Close hood.
HOOD HINGE
REMOVAL
(1) Support hood on the side that requires hinge
replacement.
(2) Mark all bolt and hinge attachment locations
with a grease pencil or other suitable device to pro-
vide reference marks for installation. When installing
hood hinge, align all marks and secure bolts. The
hood should be aligned to 4 mm (0.160 in.) gap to the
front fenders and flush across the top surfaces along
fenders. Shims can be added or removed under hood
hinge to achieve proper hood height.
(3) Remove bolts holding hood to hinge.
(4) Remove bolts holding hood hinge to load beam
flange and separate hinge from vehicle. If necessary,
paint new hinge before installation.
INSTALLATION
(1) If necessary, paint new hinge before installa-
tion.
(2) Place hinge in position on vehicle.
(3) Install bolts to hold hood hinge to front fender
flange.
(4) Install bolts to hold hood to hinge.
(5) Align all marks and secure bolts. The hood
should be aligned to 4 mm (0.160 in.) gap to the front
fenders and flush across the top surfaces along fend-
ers. Shims can be added or removed under hood
hinge to achieve proper hood height.
(6) Remove support from under hood and verify
hood operation.
Fig. 19 Hood Release Cable
1 ± HOOD RELEASE HANDLE
2 ± COWL SIDE TRIM PANEL
23 - 26 BODYPL
REMOVAL AND INSTALLATION (Continued)

Page 1169 of 1285

DODGE NEON 2000 Service Repair Manual (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)

Page 1170 of 1285

DODGE NEON 2000 Service Repair Manual (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

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