Dodge Neon / Neon SRT-4. Manual — part 400
(3) Remove cowl cover.
(4) Place protective covers over instrument panel
and hood.
(5) Remove the screws and remove the windshield
A-pillar moldings. (Fig. 2)
(6) Using a sharp cold knife, cut urethane adhe-
sive holding the windshield to the A-pillars, roof
header and cowl pinch weld fences (Fig. 3). A power
cutting device can be used if available.
(7) Separate windshield from vehicle.
INTERIOR METHOD
The urethane adhesive holding the windshield to
the opening pinch weld (fence) can be cut using a
sharp cold knife from the exterior of the vehicle.
Using the cold knife method is effective if the wind-
shield is already broken. If the glass must be sal-
vaged, cutting the urethane adhesive from the
interior of the vehicle using a reciprocating or oscil-
lating power knife is recommended.
(1) Remove inside rear view mirror.
(2) Remove instrument panel top cover, refer to
Group 8E, Instrument Panel.
(3) Remove A-pillar trim covers.
(4) Place protective covers over instrument panel
and hood.
(5) Using a reciprocating or oscillating power
knife, cut urethane adhesive holding the windshield
to the A-pillars, roof header and cowl pinch weld
fences. Refer to instructions provided with the equip-
ment being used.
(6) Remove windshield from vehicle.
Fig. 1 Rear Window Glass
1 - 9.5 MM
2 - REAR WINDOW
3 - SECTION F-F
4 - SECTION E-E
5 - 3 MM
6 - 12.7 MM
Fig. 2 WINDSHIELD HEADER OUTSIDE MOLDING
1 - WINDSHIELD HEADER MOLDING
2 - A-PILLAR OUTSIDE MOLDING
3 - A-PILLAR
23 - 84
STATIONARY GLASS
PL/SRT-4
WINDSHIELD (Continued)
INSTALLATION
CAUTION: Open the left front door glass before
installing windshield to avoid pressurizing the pas-
senger compartment. If a door is slammed before
urethane bonding is cured, water leaks can result.
Allow the urethane at least 24 hours to cure before
returning the vehicle to use.
To avoid stressing the replacement windshield, the
urethane bonding material on the windshield fence
should be smooth and consistent to the shape of
the replacement windshield. The support spacers
should be cleaned and properly installed on weld
studs or repair screws at bottom of windshield
opening.
(1) Place replacement windshield into windshield
opening and position glass in the center of the open-
ing against the support spacers.
(2) Verify the glass lays evenly against the pinch
weld fence at the sides, top and bottom of the
replacement windshield. If not, the pinch weld fence
must be formed to the shape of the new glass.
(3)
Remove replacement windshield from wind-
shield opening.
(4) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart (Fig. 4).
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER
TO
CLEAN
WINDSHIELD
BEFORE
APPLYING
GLASS
PREP AND
PRIMER.
POOR
ADHESION CAN RESULT.
(5) Clean inside of windshield with ammonia based
glass cleaner and lint-free cloth.
(6) Apply molding to Top of windshield.
(7) Apply Glass Prep adhesion promoter 25 mm (1
in.) wide around perimeter of windshield and wipe
with clean/dry lint-free cloth until no streaks are vis-
ible.
(8) Apply Glass Primer 25 mm (1 in.) wide around
perimeter of windshield. Allow at least three minutes
drying time.
(9) Using a razor knife, remove as much original
urethane as possible. Do not damage paint on wind-
shield fence.
(10) Apply pinch weld primer 15 mm (.75 in.) wide
around the windshield fence. Allow at least three
minutes drying time.
(11) Apply a 10 mm (0.4 in.) bead of urethane on
center line of windshield fence.
(12) With the aid of a helper, position the wind-
shield over the windshield opening. Align the refer-
ence marks at the bottom of the windshield to the
support spacers.
(13) Slowly lower windshield glass to windshield
opening fence. Guide the molding into proper position
as necessary. Push windshield inward molding is
flush to roof line and A-pillars (Fig. 5).
(14) Clean access urethane from exterior with
Mopar
t, Super Clean or equivalent.
(15) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)
masking tape spaced 250 mm (10 in.) apart to hold
molding in place until urethane cures.
(16) Install A-pillar moldings.
(17) Install cowl cover and wipers.
(18) Install inside rear view mirror.
(19) After urethane has cured, remove tape strips
and water test windshield to verify repair.
Fig. 3 Cut Urethane Around Windshield
1 - COLD KNIFE
2 - WINDSHIELD
Fig. 4 Work Surface Set up and Molding Installation
1 - WINDSHIELD AND MOLDINGS
2 - URETHANE BEAD AROUND GLASS 7mm (.3 in.) FROM EDGE
3 - BLOCKS
PL/SRT-4
STATIONARY GLASS
23 - 85
WINDSHIELD (Continued)
Fig. 5 Lower Windshield Into Position
1 - WINDSHIELD
2 - WINDSHIELD TO FENCE RETAINER
3 - SECTION D-D
4 - SECTION B-B
5 - SECTION C-C
6 - SECTION A-A
(FENCE)
7 - SECTION A-A
(GLASS)
8 - HIGH VISCOSITY ADHESIVE
9 - WINDSHIELD FENCE SUPPORT SPACERS
23 - 86
STATIONARY GLASS
PL/SRT-4
WINDSHIELD (Continued)
WEATHERSTRIP/SEALS
TABLE OF CONTENTS
page
page
B-PILLAR WEATHERSTRIP CHANNEL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
. . . . . . . . . . . . . . . . . . . . . . . . . 87
FDR GLASS RUN WEATHERSTRIP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
. . . . . . . . . . . . . . . . . . . . . . . . . 87
OUTER BELT WEATHERSTRIP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
. . . . . . . . . . . . . . . . . . . . . . . . . 88
DOOR UPPER SECONDARY WEATHERSTRIP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
. . . . . . . . . . . . . . . . . . . . . . . . . 89
FRONT/REAR DOOR INNER BELT
WEATHERSTRIP
REMOVAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
. . . . . . . . . . . . . . . . . . . . . . . . . 89
REAR DOOR GLASS RUN WEATHERSTRIP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
. . . . . . . . . . . . . . . . . . . . . . . . . 89
RDR SECONDARY WEATHERSTRIP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
. . . . . . . . . . . . . . . . . . . . . . . . . 90
ROOF RAIL WEATHERSTRIP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
. . . . . . . . . . . . . . . . . . . . . . . . . 90
ROOF RAIL WEATHERSTRIP RETAINR
CHANNEL
REMOVAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
. . . . . . . . . . . . . . . . . . . . . . . . . 91
SECONDARY SILL WEATHERSTRIP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
. . . . . . . . . . . . . . . . . . . . . . . . . 91
TRUNK OPENING WEATHERSTRIP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
. . . . . . . . . . . . . . . . . . . . . . . . . 92
B-PILLAR WEATHERSTRIP
CHANNEL
REMOVAL
(1) Remove b-pillar applique. (Refer to 23 - BODY/
DOOR - FRONT/APPLIQUE - REMOVAL)
(2) Remove push in fasteners attaching weather-
strip to b-pillar.
(3) Pull weatherstrip from b-pillar channels.
(4) Remove screws attaching channels to b-pillar.
(5) Remove channels from b-pillar.
INSTALLATION
(1) Install channels from b-pillar.
(2) Install screws attaching channels to b-pillar.
(3) Install weatherstrip to b-pillar channels.
(4) Install push in fasteners attaching weather-
strip to b-pillar.
(5) Install b-pillar applique. (Refer to 23 - BODY/
DOOR - FRONT/APPLIQUE - INSTALLATION)
FDR 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. 1).
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.
PL/SRT-4
WEATHERSTRIP/SEALS
23 - 87
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