SUBJECT: Front Door Glass Adjustment Procedure
NO: 23-58-95
GROUP: Body
DATE: Sep. 15, 1995
MODELS: 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO TWO-DOOR VEHICLES.
DISCUSSION: The following is a comprehensive procedure for two-door model front glass adjustment when handling wind noise and/or water leaks complaints
VISUAL INSPECTION:
First, check the fit of the door to the body to determine if the entire door must be repositioned. Then inspect the glass.

With the vehicle in the shop, close the opposite side door with the glass up all the way and the door with the problem open.Roll the glass to be examined up all the way. Close the door with a mild slam. Visually check the glass position relative to the weather-strip. The upper portion of the glass should be positioned under the weather-strip lip and the edge of the glass should be compressing the weather-strip. Check to see if any areas are not under the lip. Also check to see that the mirror stanchion also tucks under the weather-strip lip. Check to see that the glass is compressing the weather-strip seal by placing apiece of paper between the glass and the weather-strip at several locations, as the door is closed. A constant drag should be felt in all locations. If the glass position is not proper, the IN/OUT POSITION, UP-STOP, and/or SIDE VIEW ROTATION of the glass will need to be adjusted.

Check the glass position to the weather-strip retainer along the top of the glass. Close the door to the secondary latch position so that the glass just touches the lip of the weather-strip.Visually inspect the edge of glass position to the weatherstrip retainer. The glass should fit under the retainer, and the gap between the two should be consistent. If adjustments are required, first set the SIDE VIEW ROTATION POSITION.

Check the glass position relative to the B-pillar weather-strip.Visually check for gaps between the glass and weather-strip. The glass should be in constant contact with the weather-strip. Use the paper drag test along the B-pillar as described above. If the glass to weather-strip seal is not correct, the FORE/AFT position of the glass will need to be adjusted.

NOTE: ALL OF THE ABOVE ADJUSTMENTS CAN EFFECT THE OTHER ADJUSTMENTS.ALWAYS CHECK THE GLASS POSITION BY CLOSING THE DOOR WITH A"MILD SLAM".
REPAIR PROCEDURE:
FORE/AFT ADJUSTMENT

The fore/aft position of the glass is adjusted by loosening the two glass to rear lift plate attaching screws until the washers spin freely. The glass can then be moved forward or rearward. Tighten the screws to 5.6 Nm (50 in-lb) to secure the glass in the desired position. This adjustment should be made with the glass in the full up position, since the glass moves forward away from the B-pillar when it is rolled down. The up-stop locking nuts may also be loosened to allow free movement of the glass and lift plates. Figure 1.

NOTE: THE FRONT GLASS TO LIFT PLATE ATTACHING SCREW DOES NOT NEED TO BE LOOSENED TO ADJUST THE GLASS.

NOTE: THE GLASS FASTENING SCREW TORQUE REQUIREMENT IS 5.6 Nm (50 IN-LB). OVER TORQUING COULD RESULT IN GLASS BREAKAGE.

After setting the FORE/AFT POSITION of the glass, perform the UPSTOP ADJUSTMENT. The up-stop position will have an effect on the fore/aft position of the glass since the glass moves down at an angle towards the lower front corner of the door. Therefore, the fore/aft adjustment may need to be fine tuned after the up-stop position is set.

SIDE VIEW POSITION OF GLASS

The side view position of the glass, or rotation adjustment is best performed with the glass down approximately 25mm (1 inch),or with the up-stops loosened, to allow the glass to rotate freely. To make this adjustment, loosen the channel attaching screw located towards the front of the door and the locking screw located towards the rear of the door. Move the locking screw up or down in the slot in the door inner panel to change the glass position. Moving the locking screw up will rotate the glass down at the front of the glass and up at the rear and vise-versa if the adjusting screw is moved down. Tighten the screws to 11.8 Nm (105 in-lb). Bring the glass up and set the up-stop position to check the fit of the glass to the weather-strip.Figure 1.

IN/OUT ADJUSTMENT OF GLASS AND MIRROR STANCHION

The in/out position of the glass and mirror stanchion, are adjusted in similar manners. Both adjustments should be made together so the glass is centered within the mirror stanchion and the glass does not drag excessively on the inboard or outboard walls of the stanchion. The in/out adjustment of the glass is made by loosening the locking nuts at the bottom of the door and then turning the jack screws with the recessed hex.Turning the jack screws, changes the lower window guide channel angle in the door and changes the angle of the glass to the body. To adjust the glass in, towards the body, loosen the locking nuts, rotate the jack screws counter-clockwise to the desired position, then secure the locking nuts to 11.8 Nm (105in-lb). Figure 1.

NOTE: THE JACKSCREWS MUST REMAIN ENGAGED TO THE CHANNEL BRACKETS.

If they are loosened too far, the glass will be unstable and/or the channel will rattle excessively. If additional inboard adjustment is required, add a 3-4mm spacer between the jackscrew washer and the door inner panel to give additional tilt to the glass. To adjust the glass out away from the body, loosen the locking nuts, and rotate the jackscrews clockwise to the desired position, then secure the locking nuts. To adjust the mirror stanchion, the mirror trim bezel and the mirror must be removed.The trim bezel is removed by prying it off of the mirror stanchion. The remote mirror adjust knob set screw should be removed if equipped. The mirror can then be removed by removing the three attaching nuts. Removal of these two parts allows for access to the three stanchion mounting screws. First loosen the mounting screws, and locking nut. Adjust the jack screw to move the stanchion in or out, similar to the door glass. Figure 2.

UP-STOP ADJUSTMENT

The Neon 2-door has two up-stop adjustments, one for the front lift plate, one for the rear lift plate. The up-stops are simply brackets which limit the height to which the glass can be raised.

To adjust the up-stops, roll the window down partially, loosen the up-stop locking nuts. The up-stop brackets will now move freely up and down. Bring the window up to the desired position,which will position the up-stop brackets. Tighten the lockingnuts. Roll the window down and then back up to verify the glass position is correct. Figure 1.

NOTE: THE FRONT AND REAR LIFT PLATES SHOULD CONTACT THE UP STOPS AT THE SAME TIME. ONE LIFT PLATE SHOULD NOT LEAD THE OTHER.
NOTE: ALL OF THE ADJUSTMENTS CAN EFFECT OTHER ADJUSTMENTS. THEREFORE, IT IS IMPORTANT THAT THE ENTIRE GLASS POSITION BE CHECKED AFTER EACH ADJUSTMENT TO DETERMINE WHETHER ADDITIONAL ADJUSTMENTS ARE REQUIRED.

POLICY: Reimbursable within the provisions of the warranty.