Dodge - Neon - Workshop Manual - 1997 - 1997

Factory Workshop Manual Make Dodge Model Neon Engine and year L4-122 2.0L DOHC VIN Y SFI (1997) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Replacement Keyless Entry Module: Service and Repair Replacement REMOVAL 1. Remove the right trim panel. 2. Disconnect wire connector from RKE module. RKE Module Location 3. Remove screws holding RKE module to instrument panel assembly. 4. Remove module. INSTALLATION - For installation, reverse above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Replacement > Page 8 Keyless Entry Module: Service and Repair Program Remote Keyless Entry Module 1. Retrieve the programming line from the upper edge of the passenger side cowl trim panel. The RKE Programming Line is a green wire with a red bullet connector. 2. Using a jumper wire, ground the RKE programming line. 3. Turn ignition switch to the ON position. 4. Press any button on the transmitter to set code. The locks will cycle to confirm programming. If there is a second transmitter it must be set at this time. Press any button on the second transmitter and wait for the locks to cycle to confirm programming. 5. Disconnect the programming line from ground. This returns the system to its normal operation mode. 6. Replace all removed components. Return programming line to its original position. Check for system operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Replacement Keyless Entry Module: Service and Repair Replacement REMOVAL 1. Remove the right trim panel. 2. Disconnect wire connector from RKE module. RKE Module Location 3. Remove screws holding RKE module to instrument panel assembly. 4. Remove module. INSTALLATION - For installation, reverse above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Replacement > Page 14 Keyless Entry Module: Service and Repair Program Remote Keyless Entry Module 1. Retrieve the programming line from the upper edge of the passenger side cowl trim panel. The RKE Programming Line is a green wire with a red bullet connector. 2. Using a jumper wire, ground the RKE programming line. 3. Turn ignition switch to the ON position. 4. Press any button on the transmitter to set code. The locks will cycle to confirm programming. If there is a second transmitter it must be set at this time. Press any button on the second transmitter and wait for the locks to cycle to confirm programming. 5. Disconnect the programming line from ground. This returns the system to its normal operation mode. 6. Replace all removed components. Return programming line to its original position. Check for system operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations System Relay And Pump Motor Relay Box Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Description and Operation > ABS System Relay ABS Main Relay: Description and Operation ABS System Relay CIRCUIT OPERATION The system relay is used for the operation of the Anti Lock Brake (ABS) system. Power for the relay is supplied on the B57 circuit from cavity 57 of the Controller Anti Lock Brake (CAB). Ground for the relay is on the Z1 circuit. This ground is spliced in with the pump motor and terminates at the left headlamp ground. When the system is operating normally power for the contact side of the relay is supplied from the CAB on the B57 circuit. It passes through the relay to the Z1 ground and terminates at the left headlamp ground. If a problem is detected in the system, the contact side of the relay switches from the Z1 to the F12 circuit. This causes the ABS warning lamp in the instrument cluster to illuminate. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Description and Operation > ABS System Relay > Page 21 ABS Main Relay: Description and Operation ABS System Relays System Relay And Pump Motor Relay Box SYSTEM RELAY The main purpose of the system relay is to put the Antilock Brake System (ABS) into a stand-by mode for ABS operation. The System Relay is energized by the Controller Antilock Brake (CAB) shortly after the ignition switch is turned on. When Energized - by the CAB, the System Relay turns off the ABS warning lamp and provides 12 volts to the CAB. This voltage can then be used by the CAB to energize the Decay Solenoids during ABS braking. When energized, the System Relay also provides the Pump/Motor Relay coil with 12 volts. The ground path to the Pump/Motor Relay is completed by the CAB during ABS braking. When De-energized - the ABS warning lamp is illuminated, voltage to the Decay Solenoids is cut off, and the Pump/Motor Relay is prevented from energizing. Typically, the System Relay is de-energized by the CAB when a fault is detected that requires turning ABS off. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Description and Operation > Description Brake Fluid Pump Relay: Description and Operation Description System Relay And Pump Motor Relay Box PURPOSE Pump/Motor power is supplied by the Pump/Motor Relay. The pump motor relay is also part of the relay box mounted to the Hydraulic Control Unit (HCU). If pump/motor relay replacement is required, it is also only serviced by the replacement of the relay box assembly. FUNCTION Voltage for the 12 volt side of the relay coil is provided by the System Relay. The ground path through the relay coil is completed by the Controller Antilock Brake (CAB) during Antilock Brake System (ABS) braking. The relay contacts are closed when the relay is energized. This provides 12 volts to the pump/motor as needed during ABS braking. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Description and Operation > Description > Page 26 Brake Fluid Pump Relay: Description and Operation Circuit Operation CIRCUIT OPERATION The Anti Lock Brake (ABS) pump motor relay controls when the pump motor runs. Power for the coil side of the relay is supplied from cavity 47 of the Controller Anti Lock Brake (CAB) on the B47 circuit. This circuit also supplies voltage for the contact side of the system relay The ground side of the coil is controlled by the B116 circuit. Circuit B116 connects to cavity 16 of the CAB connector. Circuit B120 from cavity 20 of the CAB connector powers the ABS pump motor. This circuit is also used as an input to the CAB for pump motor monitoring. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations CAB 60-Way Wiring Harness Connector Controller Antilock Brake The CAB is mounted under the instrument panel behind the drivers side kick panel of the vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 30 Electronic Brake Control Module: Description and Operation Controller Antilock Brake PURPOSE The Controller Antilock Brake (CAB) is a microprocessor based device which monitors the Antilock Brake System (ABS) during normal braking and controls it when in an ABS stop. The CAB is mounted under the instrument panel on the drivers side kick panel. The CAB uses a 60 way electrical connector on the vehicle wiring harness. The power source for the CAB is through the ignition switch in the Run or On position. NOTE: The CAB is not on the Chrysler Collision Detection (CCD) bus. THE PRIMARY FUNCTIONS OF THE CAB - Detect wheel locking tendencies. - Control fluid modulation to the brakes while in ABS mode. - Monitor the system for proper operation. - Provide communication to the DRB scan tool while in diagnostic mode. The CAB Continuously Monitors - the speed of each wheel through the signals generated at the Wheel Speed Sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the CAB commands the Hydraulic Control Unit (HCU) to modulate brake fluid pressure in some or all of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The ABS System Is Constantly Monitored - by the CAB for proper operation. If the CAB detects a fault, it will turn on the Amber ABS Warning Lamp and disable the ABS braking system. The normal Non ABS braking system will remain operational. The CAB Contains A Self-diagnostic Program - which will turn on the Amber ABS Warning Lamp when a ABS system fault is detected. Faults Are Then Stored - in a diagnostic program memory. There are multiple fault messages which may be stored in the CAB and displayed through the DRB. These fault messages will remain in the CAB memory even after the ignition has been turned off. The fault messages can be cleared by using the DRB diagnostics tester, or they will be automatically cleared from the memory after the vehicle is driven approximately 3500 miles. CONTROLLER ANTILOCK BRAKE INPUTS ^ Four wheel speed sensors. ^ Stop lamp switch. ^ Ignition switch. ^ System relay voltage. ^ Ground. ^ Pump/Motor Relay Monitor ^ Diagnostics Communications CONTROLLER ANTILOCK BRAKE OUTPUTS ^ 4 Decay Solenoids ^ ABS warning lamp. ^ System relay actuation. ^ Diagnostic communication. ^ Pump motor relay actuation Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 31 Electronic Brake Control Module: Service and Repair Controller Antilock Brake REMOVE 1. Turn vehicle ignition off. CAB 60-Way Wiring Harness Connector 2. Disconnect the wiring harness 60 way connector from the Controller Antilock Brake Module (CAB). Verify that the vehicle ignition is off before removing the 60 way connector. CAB Bracket To Kick Panel Mounting 3. Remove the 2 controller bracket to drivers side cowl mounting nuts. 4. Remove the CAB from the vehicle. INSTALL 1. Install CAB and mounting bracket on mounting studs located on passenger side kick panel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 32 2. Install the 2 CAB bracket mounting nuts and securely tighten. 3. Install the 60-way wiring harness connector by hand into the 60-way CAB connector, as far as possible. Then use the CAB connector retaining bolt to fully seat wiring harness connector into the CAB. 4. Torque the 60-way connector retaining bolt to 4 Nm (38 inch lbs.). 5. If a new CAB is being has been installed, it must be initialized prior to the vehicle being driven. The CAB is initialized using the DRB Scan Tool and the initializing procedure described upon selecting Bendix ABX-4 Diagnostics. New controllers are programmed to flash the ABS warning lamp until initialized by the installing technician. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7692 > May > 98 > Recall- Radiator Fan Relay Technical Service Bulletin # 7692 Date: 980501 Recall- Radiator Fan Relay No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay Models: 1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. IMPORTANT: This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan Relay Packages, PN CKF07690, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 1 Wiring Jumper Assembly 2 Tie Straps California Recall Completion Label Requirement There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealers are requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 42 Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action please contact your Zone Service Office. A. Install the Jumper Harness 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Raise the vehicle on an appropriate hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 43 3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1). 4. Disconnect the fan motor wiring harness connector from the fan support (if necessary). 5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support. 6. Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that the connector faces toward the outboard (left) side of the vehicle (Figure 2). 7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2). 8. Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the locked position. 9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position. 10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps. NOTE: Make sure that the wiring does not interfere with any other components. B. Replace the Radiator Fan Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 44 1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3). 2. Disconnect the radiator fan relay wiring connector. 3. Remove and discard the radiator fan relay. 4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws. 5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 6. Lower the vehicle. 7. Connect the negative battery cable. C. Install the Authorized Label 1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086). 2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment. D. Complete Proof of Correction Form 1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^ This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant ("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. ^ Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number for TSB 07-07-97 and 07-04-98 is being canceled. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 45 ^ For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of those vehicles. Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is... The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumper harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. How the state knows that the recall has been performed... State of California regulations require Chrysler to provide the Department of Motor Vehicles with a record of all vehicles which have not had the recall service performed. If your vehicle is not on this list the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We are sorry for any inconvenience but trust you understand our interest in clean air and in your continued satisfaction with our products. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7691 > May > 98 > Recall - Radiator Fan Relay Technical Service Bulletin # 7691 Date: 980501 Recall - Radiator Fan Relay No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay Models: 1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. IMPORTANT: This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan Relay Packages, PN CKF07690, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 1 Wiring Jumper Assembly 2 Tie Straps California Recall Completion Label Requirement There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealers are requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 50 Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action please contact your Zone Service Office. A. Install the Jumper Harness 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Raise the vehicle on an appropriate hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 51 3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1). 4. Disconnect the fan motor wiring harness connector from the fan support (if necessary). 5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support. 6. Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that the connector faces toward the outboard (left) side of the vehicle (Figure 2). 7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2). 8. Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the locked position. 9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position. 10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps. NOTE: Make sure that the wiring does not interfere with any other components. B. Replace the Radiator Fan Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 52 1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3). 2. Disconnect the radiator fan relay wiring connector. 3. Remove and discard the radiator fan relay. 4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws. 5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 6. Lower the vehicle. 7. Connect the negative battery cable. C. Install the Authorized Label 1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086). 2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment. D. Complete Proof of Correction Form 1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^ This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant ("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. ^ Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number for TSB 07-07-97 and 07-04-98 is being canceled. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 53 ^ For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of those vehicles. Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is... The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumper harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... ^ If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If you are still unable to obtain the repair as described in this letter within a reasonable time, you may also contact the Vehicle Programs and Compliance Division of the Environmental Protection Agency (6405J), 401 M Street, S.W., Washington, D.C. 20460. In order to ensure your full protection under the emission warranty made applicable to your vehicle under Federal law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack of proper maintenance of your vehicle. Further, without this repair your vehicle may fail a state or local emission inspection test. We're sorry for any inconvenience, but trust that you understand our interest in clean air and your continuing satisfaction with our product. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats Technical Service Bulletin # 07-04-98 Date: 980417 Cooling System - Fan ON Continuously/Overheats NO: 07-04-98 GROUP: Cooling DATE: Apr. 17, 1998 SUBJECT: Vehicle Overheats (Radiator Fan Inoperative) Or Radiator Fan Runs Continuously THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-97 DATED FEBRUARY 20, 1998 WHICH SHOULD BE NOTED IN THE 1997 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-98004). THE REVISION PROVIDES A NEW PART NUMBER FOR THE RADIATOR FAN RELAY. THE CHANGE IS HIGHLIGHTED WITH ASTERISKS. MODELS: 1997 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT AT TOLUCA ASSEMBLY PRIOR TO SEPTEMBER 11, 1997 (MDH 0911XX). TOLUCA ASSEMBLY IS DESIGNATED BY A "T" IN THE ELEVENTH POSITION OF THE VEHICLE IDENTIFICATION NUMBER. SYMPTOM/CONDITION: Vehicle overheats or radiator fan continues to run. DIAGNOSIS: Actuate the radiator fan relay using the DRB III. If the radiator fan does not come on or fan runs continuously, perform the Repair Procedure. PARTS REQUIRED: 1 05293157AA Jumper Wire With Diode, Radiator Fan **1 04707286 Relay, Radiator Fan** 2 06015756 Tie Strap POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-12-92 0.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves installing a radiator fan jumper wire assembly into the headlamp and dash wiring harness, and replacing the solid state relay. 1. Raise the hood and disconnect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 59 2. Raise the vehicle on a suitable hoist. 3. Locate the left (driver's side) black fan motor connector. Retract the red latch on the two-way female connector, depress the thumb latch, and disconnect the connector from the fan (Figure 1). If the wiring to the fan motor is clipped into the fan support, gently pry it out of the hole so the fan is not damaged. 4. Pry out the two christmas tree type retainers located on the lower radiator enclosure reinforcement. 5. Install the jumper wire assembly (p/n 052931 57AA) between the radiator fan and the headlamp and dash harness: A. Attach the black two-way male connector with the clip into the outboard hole, so the connector faces outboard toward the left side of the vehicle. Attach the second clip into the inboard hole of the lower reinforcement that the original wiring came out of (Figure 2). B. Connect the original two-way black connector to the new mating connector installed in the previous step and slide the red latch into the locked position. 6. Connect the two-way female black connector on the new jumper assembly to the fan connector and slide the red latch into the locked position. If the original wiring to the fan was clipped into the fan support, snap the new clip on the jumper into the same hole. 7. Bundle the excess original fan wiring and tie strap to the main bundle of vehicle wiring in the front left corner in two places. NOTE: ENSURE THAT THE WIRING BUNDLE IS SECURE AND DOES NOT INTERFERE WITH ANY OTHER COMPONENTS. 8. The solid state fan relay is located on the left front rail. Retract the red latch on the black four-way connector and disconnect from the solid state fan relay. 9. Remove the two screws that secure the relay to the side of the left front rail and remove the relay. 10. Install the new solid state fan relay ** (p/n 04707286)** and locate the index pin on the relay into the locator hole in the rail. Secure with the two screws and torque to 5 N.m (45 in.lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 60 11. Connect the four way connector and slide the red latch into the locked position. 12. Lower the vehicle and connect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions Solid State Fan Relay: All Technical Service Bulletins Cooling System - Cooling Fan Relay Pin-Out Revisions NUMBER: 26-06-98D GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.0L, 2.4L, 2.5L, 3.3L, 3.5L SFI Diagnostic Manual - Publication Number 81-699-96040 DESCRIPTION OF CHANGES Revision to the PL body radiator fan relay connector pin out Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 66 10 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 67 49 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 68 110 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 69 111 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay Technical Service Bulletin # 7692 Date: 980501 Recall- Radiator Fan Relay No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay Models: 1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. IMPORTANT: This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan Relay Packages, PN CKF07690, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 1 Wiring Jumper Assembly 2 Tie Straps California Recall Completion Label Requirement There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealers are requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 74 Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action please contact your Zone Service Office. A. Install the Jumper Harness 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Raise the vehicle on an appropriate hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 75 3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1). 4. Disconnect the fan motor wiring harness connector from the fan support (if necessary). 5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support. 6. Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that the connector faces toward the outboard (left) side of the vehicle (Figure 2). 7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2). 8. Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the locked position. 9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position. 10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps. NOTE: Make sure that the wiring does not interfere with any other components. B. Replace the Radiator Fan Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 76 1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3). 2. Disconnect the radiator fan relay wiring connector. 3. Remove and discard the radiator fan relay. 4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws. 5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 6. Lower the vehicle. 7. Connect the negative battery cable. C. Install the Authorized Label 1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086). 2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment. D. Complete Proof of Correction Form 1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^ This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant ("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. ^ Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number for TSB 07-07-97 and 07-04-98 is being canceled. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 77 ^ For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of those vehicles. Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is... The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumper harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. How the state knows that the recall has been performed... State of California regulations require Chrysler to provide the Department of Motor Vehicles with a record of all vehicles which have not had the recall service performed. If your vehicle is not on this list the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We are sorry for any inconvenience but trust you understand our interest in clean air and in your continued satisfaction with our products. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay Technical Service Bulletin # 7691 Date: 980501 Recall - Radiator Fan Relay No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay Models: 1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. IMPORTANT: This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan Relay Packages, PN CKF07690, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 1 Wiring Jumper Assembly 2 Tie Straps California Recall Completion Label Requirement There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealers are requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 82 Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action please contact your Zone Service Office. A. Install the Jumper Harness 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Raise the vehicle on an appropriate hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 83 3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1). 4. Disconnect the fan motor wiring harness connector from the fan support (if necessary). 5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support. 6. Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that the connector faces toward the outboard (left) side of the vehicle (Figure 2). 7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2). 8. Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the locked position. 9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position. 10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps. NOTE: Make sure that the wiring does not interfere with any other components. B. Replace the Radiator Fan Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 84 1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3). 2. Disconnect the radiator fan relay wiring connector. 3. Remove and discard the radiator fan relay. 4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws. 5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 6. Lower the vehicle. 7. Connect the negative battery cable. C. Install the Authorized Label 1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086). 2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment. D. Complete Proof of Correction Form 1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^ This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant ("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. ^ Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number for TSB 07-07-97 and 07-04-98 is being canceled. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 85 ^ For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of those vehicles. Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is... The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumper harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... ^ If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If you are still unable to obtain the repair as described in this letter within a reasonable time, you may also contact the Vehicle Programs and Compliance Division of the Environmental Protection Agency (6405J), 401 M Street, S.W., Washington, D.C. 20460. In order to ensure your full protection under the emission warranty made applicable to your vehicle under Federal law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack of proper maintenance of your vehicle. Further, without this repair your vehicle may fail a state or local emission inspection test. We're sorry for any inconvenience, but trust that you understand our interest in clean air and your continuing satisfaction with our product. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats Technical Service Bulletin # 07-04-98 Date: 980417 Cooling System - Fan ON Continuously/Overheats NO: 07-04-98 GROUP: Cooling DATE: Apr. 17, 1998 SUBJECT: Vehicle Overheats (Radiator Fan Inoperative) Or Radiator Fan Runs Continuously THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-97 DATED FEBRUARY 20, 1998 WHICH SHOULD BE NOTED IN THE 1997 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-98004). THE REVISION PROVIDES A NEW PART NUMBER FOR THE RADIATOR FAN RELAY. THE CHANGE IS HIGHLIGHTED WITH ASTERISKS. MODELS: 1997 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT AT TOLUCA ASSEMBLY PRIOR TO SEPTEMBER 11, 1997 (MDH 0911XX). TOLUCA ASSEMBLY IS DESIGNATED BY A "T" IN THE ELEVENTH POSITION OF THE VEHICLE IDENTIFICATION NUMBER. SYMPTOM/CONDITION: Vehicle overheats or radiator fan continues to run. DIAGNOSIS: Actuate the radiator fan relay using the DRB III. If the radiator fan does not come on or fan runs continuously, perform the Repair Procedure. PARTS REQUIRED: 1 05293157AA Jumper Wire With Diode, Radiator Fan **1 04707286 Relay, Radiator Fan** 2 06015756 Tie Strap POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-12-92 0.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves installing a radiator fan jumper wire assembly into the headlamp and dash wiring harness, and replacing the solid state relay. 1. Raise the hood and disconnect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 90 2. Raise the vehicle on a suitable hoist. 3. Locate the left (driver's side) black fan motor connector. Retract the red latch on the two-way female connector, depress the thumb latch, and disconnect the connector from the fan (Figure 1). If the wiring to the fan motor is clipped into the fan support, gently pry it out of the hole so the fan is not damaged. 4. Pry out the two christmas tree type retainers located on the lower radiator enclosure reinforcement. 5. Install the jumper wire assembly (p/n 052931 57AA) between the radiator fan and the headlamp and dash harness: A. Attach the black two-way male connector with the clip into the outboard hole, so the connector faces outboard toward the left side of the vehicle. Attach the second clip into the inboard hole of the lower reinforcement that the original wiring came out of (Figure 2). B. Connect the original two-way black connector to the new mating connector installed in the previous step and slide the red latch into the locked position. 6. Connect the two-way female black connector on the new jumper assembly to the fan connector and slide the red latch into the locked position. If the original wiring to the fan was clipped into the fan support, snap the new clip on the jumper into the same hole. 7. Bundle the excess original fan wiring and tie strap to the main bundle of vehicle wiring in the front left corner in two places. NOTE: ENSURE THAT THE WIRING BUNDLE IS SECURE AND DOES NOT INTERFERE WITH ANY OTHER COMPONENTS. 8. The solid state fan relay is located on the left front rail. Retract the red latch on the black four-way connector and disconnect from the solid state fan relay. 9. Remove the two screws that secure the relay to the side of the left front rail and remove the relay. 10. Install the new solid state fan relay ** (p/n 04707286)** and locate the index pin on the relay into the locator hole in the rail. Secure with the two screws and torque to 5 N.m (45 in.lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 91 11. Connect the four way connector and slide the red latch into the locked position. 12. Lower the vehicle and connect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions Solid State Fan Relay: All Technical Service Bulletins Cooling System - Cooling Fan Relay Pin-Out Revisions NUMBER: 26-06-98D GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.0L, 2.4L, 2.5L, 3.3L, 3.5L SFI Diagnostic Manual - Publication Number 81-699-96040 DESCRIPTION OF CHANGES Revision to the PL body radiator fan relay connector pin out Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 97 10 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 98 49 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 99 110 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 100 111 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats Technical Service Bulletin # 07-04-98 Date: 980417 Cooling System - Fan ON Continuously/Overheats NO: 07-04-98 GROUP: Cooling DATE: Apr. 17, 1998 SUBJECT: Vehicle Overheats (Radiator Fan Inoperative) Or Radiator Fan Runs Continuously THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-97 DATED FEBRUARY 20, 1998 WHICH SHOULD BE NOTED IN THE 1997 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-98004). THE REVISION PROVIDES A NEW PART NUMBER FOR THE RADIATOR FAN RELAY. THE CHANGE IS HIGHLIGHTED WITH ASTERISKS. MODELS: 1997 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT AT TOLUCA ASSEMBLY PRIOR TO SEPTEMBER 11, 1997 (MDH 0911XX). TOLUCA ASSEMBLY IS DESIGNATED BY A "T" IN THE ELEVENTH POSITION OF THE VEHICLE IDENTIFICATION NUMBER. SYMPTOM/CONDITION: Vehicle overheats or radiator fan continues to run. DIAGNOSIS: Actuate the radiator fan relay using the DRB III. If the radiator fan does not come on or fan runs continuously, perform the Repair Procedure. PARTS REQUIRED: 1 05293157AA Jumper Wire With Diode, Radiator Fan **1 04707286 Relay, Radiator Fan** 2 06015756 Tie Strap POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-12-92 0.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves installing a radiator fan jumper wire assembly into the headlamp and dash wiring harness, and replacing the solid state relay. 1. Raise the hood and disconnect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 105 2. Raise the vehicle on a suitable hoist. 3. Locate the left (driver's side) black fan motor connector. Retract the red latch on the two-way female connector, depress the thumb latch, and disconnect the connector from the fan (Figure 1). If the wiring to the fan motor is clipped into the fan support, gently pry it out of the hole so the fan is not damaged. 4. Pry out the two christmas tree type retainers located on the lower radiator enclosure reinforcement. 5. Install the jumper wire assembly (p/n 052931 57AA) between the radiator fan and the headlamp and dash harness: A. Attach the black two-way male connector with the clip into the outboard hole, so the connector faces outboard toward the left side of the vehicle. Attach the second clip into the inboard hole of the lower reinforcement that the original wiring came out of (Figure 2). B. Connect the original two-way black connector to the new mating connector installed in the previous step and slide the red latch into the locked position. 6. Connect the two-way female black connector on the new jumper assembly to the fan connector and slide the red latch into the locked position. If the original wiring to the fan was clipped into the fan support, snap the new clip on the jumper into the same hole. 7. Bundle the excess original fan wiring and tie strap to the main bundle of vehicle wiring in the front left corner in two places. NOTE: ENSURE THAT THE WIRING BUNDLE IS SECURE AND DOES NOT INTERFERE WITH ANY OTHER COMPONENTS. 8. The solid state fan relay is located on the left front rail. Retract the red latch on the black four-way connector and disconnect from the solid state fan relay. 9. Remove the two screws that secure the relay to the side of the left front rail and remove the relay. 10. Install the new solid state fan relay ** (p/n 04707286)** and locate the index pin on the relay into the locator hole in the rail. Secure with the two screws and torque to 5 N.m (45 in.lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 106 11. Connect the four way connector and slide the red latch into the locked position. 12. Lower the vehicle and connect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 112 10 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 113 49 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 114 110 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 115 111 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay Technical Service Bulletin # 7692 Date: 980501 Recall- Radiator Fan Relay No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay Models: 1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. IMPORTANT: This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan Relay Packages, PN CKF07690, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 1 Wiring Jumper Assembly 2 Tie Straps California Recall Completion Label Requirement There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealers are requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 120 Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action please contact your Zone Service Office. A. Install the Jumper Harness 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Raise the vehicle on an appropriate hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 121 3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1). 4. Disconnect the fan motor wiring harness connector from the fan support (if necessary). 5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support. 6. Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that the connector faces toward the outboard (left) side of the vehicle (Figure 2). 7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2). 8. Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the locked position. 9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position. 10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps. NOTE: Make sure that the wiring does not interfere with any other components. B. Replace the Radiator Fan Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 122 1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3). 2. Disconnect the radiator fan relay wiring connector. 3. Remove and discard the radiator fan relay. 4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws. 5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 6. Lower the vehicle. 7. Connect the negative battery cable. C. Install the Authorized Label 1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086). 2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment. D. Complete Proof of Correction Form 1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^ This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant ("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. ^ Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number for TSB 07-07-97 and 07-04-98 is being canceled. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 123 ^ For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of those vehicles. Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is... The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumper harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. How the state knows that the recall has been performed... State of California regulations require Chrysler to provide the Department of Motor Vehicles with a record of all vehicles which have not had the recall service performed. If your vehicle is not on this list the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We are sorry for any inconvenience but trust you understand our interest in clean air and in your continued satisfaction with our products. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay Technical Service Bulletin # 7691 Date: 980501 Recall - Radiator Fan Relay No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay Models: 1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. IMPORTANT: This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan Relay Packages, PN CKF07690, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 1 Wiring Jumper Assembly 2 Tie Straps California Recall Completion Label Requirement There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealers are requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 128 Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action please contact your Zone Service Office. A. Install the Jumper Harness 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Raise the vehicle on an appropriate hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 129 3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1). 4. Disconnect the fan motor wiring harness connector from the fan support (if necessary). 5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support. 6. Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that the connector faces toward the outboard (left) side of the vehicle (Figure 2). 7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2). 8. Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the locked position. 9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position. 10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps. NOTE: Make sure that the wiring does not interfere with any other components. B. Replace the Radiator Fan Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 130 1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3). 2. Disconnect the radiator fan relay wiring connector. 3. Remove and discard the radiator fan relay. 4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws. 5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 6. Lower the vehicle. 7. Connect the negative battery cable. C. Install the Authorized Label 1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086). 2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment. D. Complete Proof of Correction Form 1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^ This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant ("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. ^ Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number for TSB 07-07-97 and 07-04-98 is being canceled. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 131 ^ For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of those vehicles. Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is... The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumper harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... ^ If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If you are still unable to obtain the repair as described in this letter within a reasonable time, you may also contact the Vehicle Programs and Compliance Division of the Environmental Protection Agency (6405J), 401 M Street, S.W., Washington, D.C. 20460. In order to ensure your full protection under the emission warranty made applicable to your vehicle under Federal law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack of proper maintenance of your vehicle. Further, without this repair your vehicle may fail a state or local emission inspection test. We're sorry for any inconvenience, but trust that you understand our interest in clean air and your continuing satisfaction with our product. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Page 132 Solid State Fan Relay: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Page 133 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Page 134 Solid State Relay Solid State Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions Solid State Fan Relay: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 137 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 138 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 139 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 140 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 141 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 142 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 143 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 144 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 145 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 146 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 147 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 148 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 149 Solid State Fan Relay: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 150 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 151 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 152 Radiator Fan Relay Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 153 Solid State Fan Relay: Electrical Diagrams Dual Cooling Fans A/C & Heater System -- Sheet 8w-42-4 Chrysler Does not provide a wiring diagram for dual fans on 95-98 model year Neons. This diagram is for the 99 model year and is presented for reference only. Single Cooling Fan Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 154 A/C And Heat Part 1 of 4 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 155 A/C And Heat Part 2 Of 4 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 156 A/C And Heat Part 3 Of 4 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 157 A/C And Heat Part 4 Of 4 The OE does not show a wiring diagram showing the dual fan option specifically until 1999 but the dual fan option is mentioned. Additionally, the Radiator Fan Control is shown as a portion of the A/C circuit and as a portion of the PCM circuit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Page 158 Solid State Fan Relay: Description and Operation Radiator Fan Control Module -PCM Output The radiator fan runs when coolant temperature and A/C system pressure demand cooling. The radiator fan circuit contains a Pulse Width Module (PWM) this is shown on the wiring as the Solid State Fan Relay. A 5 volt signal is supplied to the PWM. The PCM provides a pulsed ground for the PWM. Depending upon the amount of pulse on time, the PWM puts out a proportional voltage to the fan motor at the lower speed. For instance, if the on time is 30 percent, then the voltage to the fan motor will be 3.6 volts. When engine coolant reaches approximately 99°C (210°F) the PCM grounds the PWM relay. When the PCM grounds the relay it operates at a 30% duty cycle and immediately ramps up to 100% duty cycle. The PCM de-energizes the PWM relay when coolant temperature drops to approximately 93°C (199°F). Also, when the air conditioning pressure switch closes, the PCM grounds the PWM. The air conditioning switch closes at 285 psi ± 10 psi. When air conditioning pressure drops approximately 40 psi, the pressure switch opens and the fan turns off. The PWM relay is located on the left front inner frame just behind the radiator. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Power Distribution Center (Top) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Solid State Relay The relay is located on the left front inner frame just behind the radiator. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 166 Condenser Fan Motor Relay: Description and Operation Radiator Fan Control Module -PCM Output The radiator fan runs when coolant temperature and A/C system pressure demand cooling. The radiator fan circuit contains a Pulse Width Module (PWM) this is shown on the wiring as the Solid State Fan Relay. A 5 volt signal is supplied to the PWM. The PCM provides a pulsed ground for the PWM. Depending upon the amount of pulse on time, the PWM puts out a proportional voltage to the fan motor at the lower speed. For instance, if the on time is 30 percent, then the voltage to the fan motor will be 3.6 volts. When engine coolant reaches approximately 99°C (210°F) the PCM grounds the PWM relay. When the PCM grounds the relay it operates at a 30% duty cycle and immediately ramps up to 100% duty cycle. The PCM de-energizes the PWM relay when coolant temperature drops to approximately 93°C (199°F). Also, when the air conditioning pressure switch closes, the PCM grounds the PWM. The air conditioning switch closes at 285 psi ± 10 psi. When air conditioning pressure drops approximately 40 psi, the pressure switch opens and the fan turns off. The PWM relay is located on the left front inner frame just behind the radiator. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Description and Operation Battery Discharge Protection Relay: Description and Operation Halo Lamp/Time Delay Relay CIRCUIT OPERATION The time delay relay is used to allow a time-ON function for the ignition switch halo lamp. Power for the relay is received on the M1 circuit from the 10 Amp fuse located in the Power Distribution Center (PDC). This is the Ignition-Off Draw (IOD) fuse and HOT at all times. When a door is OPENED, or the headlamp switch is moved to the dome lamp position, a ground path is provided for the relay on the M23 circuit. This energizes the relay, CLOSING the contacts. When the relay contacts are CLOSED, power is provided through the relay to the M50 circuit. The M50 circuit supplies current to the ignition switch lamp in the steering column. Ground for the lamp is provided on the Z3 circuit. This circuit splices with the glove box lamp, the ash receiver lamp, and the PRNDL lamp. The Z3 circuit terminates at the instrument panel left center support. Circuit M23 is also spliced with the Remote Key-less Entry (RKE) module and the time out relay located in the fuse block. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations DRL Module The Daytime Running Lamp module is attached to a support brace on the underside of the instrument panel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 174 Daytime Running Lamp Control Unit: Description and Operation CIRCUIT OPERATION - CANADA On vehicles built for sale in Canada, the head- lamps operate, at reduced intensity, when the ignition switch is in the RUN position and the parking brake switch is OPEN. In the Power Distribution Center (PDC), a bus bar connected to battery voltage feeds circuit A1. In the RUN position, the ignition switch connects circuit A1 to circuit A21. A 30 Amp fuse in the PDC, protects circuits A1 and A21. Circuit A21 connects to a bus bar in the fuse block. The bus bar in the fuse block feeds circuit G5 through a 5 Amp fuse in cavity 11. Circuit G5 is powered only when the ignition switch is in the RUN position. Circuit G9 connects to the DRL module. The G9 circuit splices to the brake warning switch, park brake switch and instrument cluster brake warning bulb. Circuit L20 from the headlamp and dimmer switch supplies battery voltage to the DRL module at all times. Circuit A3 from the PDC feeds circuit L20. A 40 Amp fuse in the PDC protects the A3 circuit. From the DRL module, circuit L4 powers the LOW beams of the left and right headlamps. The DRL controls the power to circuit L4. Circuit L4 connects to cavity 10 of the DRL module. Circuit L3 feeds the high beams of the headlamps. When the operator flashes the headlamps with the stalk of the multi-function switch, the DRL senses voltage on circuit L3. When it senses voltage on circuit L3, the DRL module stops supplying power to the low beams on circuit L4. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 175 Daytime Running Lamp Control Unit: Testing and Inspection - If the park brake switch is CLOSED, the DRL will not turn on the headlamps. The DRL senses if the park brake switch is CLOSED on circuit G9. - Circuit Z1 provides ground for the headlamps. - Circuit L20 of the headlamp switch connector has a jumper that feeds the DRL module. - Check for a blown fuse in circuits A1 or G5. - The headlamp switch has a 24 Amp circuit breaker that feeds circuit L20. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Power Distribution Center Relay Locations Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Service and Repair Headlamp Control Module: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. From behind bumper fascia, remove bolt holding outboard end of module to fender. 3. Loosen bolts holding inboard end of module to radiator closure panel. 4. Remove bolt holding grille to headlamp module. Headlamp Module 5. Remove bolts holding top of module to upper cross member. 6. Disengage wire connector from headlamp and parking lamp sockets. 7. Separate headlamp module from vehicle. INSTALLATION - Reverse the preceding operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Component Locations Power Distribution Center (Top) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Component Locations > Page 186 Auto Shutdown Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 187 Horn Relay: Diagrams Power Distribution Center (Bottom) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 188 Power Distribution Center (Top) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 189 Horn Relay: Testing and Inspection 1. Remove horn relay. 2. Using ohmmeter, test for continuity between ground and circuit 65 of horn relay. a. When the horn switch is not depressed, no continuity should be present. b. Continuity to ground when horn switch is depressed. c. If continuity is not correct repair horn switch or wiring as necessary. 3. Insert a jumper wire between circuit 63 and 66 of the Power Distribution Center. a. If horn sounds replace relay. b. If the horn does not sound, install horn relay and refer to Horn Test. 4. Using voltmeter, test voltage at: a. Circuit 62 and 66 test for battery voltage from fuse C to body ground. b. If voltage is incorrect repair as necessary. 5. Check relay for 70 to 75 Ohms resistance from terminal 85 to 86. If resistance not OK, replace relay. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 190 Horn Relay: Service and Repair REMOVAL 1. Remove the Power Distribution Center cover and locate the horn relay. Power Distribution Center 2. Remove the horn relay. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Description and Operation Interior Lighting Relay: Description and Operation CIRCUIT OPERATION The time out relay is located in the fuse block and is used to control the ground path for various interior lamps. It will also turn the lamps OFF after a specified period of time, and works with the Remote Keyless Entry (RKE) system for illuminated entry. Circuit M2 connects to the relay and supplied a ground path through the door ajar switches. Circuit M1 is used to supply battery voltage to the relay. This circuit is produced by a 10 Amp fuse located in cavity 13 of the Power Distribution Center (PDC). Circuit M32 is connected from the relay to the various interior lamps and RKE module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Specifications Powertrain Control Module: Specifications PCM 60-Way Connector Torque = 4 Nm (35 in lb) PCM Mounting Screws = 4 Nm (35 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Specifications > Page 199 Fig. 100 Powertrain Control Module Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 202 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 203 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 204 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 205 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 206 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 207 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 208 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 209 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 210 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 211 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 212 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 213 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 214 Powertrain Control Module: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 215 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 216 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 217 Powertrain Control Module Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 218 Powertrain Control Module: Service Precautions - Before disconnecting any control module, make sure the ignition is off. Failure to do so could damage the module. - When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. - Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. - Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. - Operation of any type, including idling, should be avoided if engine misfiring occurs. Under this condition, the exhaust system operates at abnormally high temperature, which may cause damage to the catalyst or under-body parts of the vehicle. - Alteration or deterioration of ignition or fuel system, or any type of operating condition which results in engine misfiring must be corrected to avoid overheating the catalytic converter. - Proper maintenance and tune-up, according to manufacturer's specifications, should be made to correct abnormal conditions as soon as possible. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation Powertrain Control Module: Description and Operation Circuit Operation CIRCUIT OPERATION Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to cavity 46 of the Powertrain Control Module (PCM). A 20 Amp fuse in the PDC protects circuit A14. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 221 Powertrain Control Module: Description and Operation PCM Operation Fig. 100 Powertrain Control Module Fig. 3 Data Link Connector The Powertrain Control Module (PCM) is a digital computer containing a microprocessor (Fig. 2). The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. PCM Inputs: Air Conditioning Controls - Battery Voltage - Battery Temperature Sensor - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Fuel Level Sensor - Ignition Switch (A21) - Intake Air Temperature Sensor - Knock Sensor - Manifold Absolute Pressure (MAP) Sensor - Oxygen Sensors - Power Steering Pressure Switch - SCI Receiver - Speed Control Switches - Throttle Position Sensor - Transmission Park/Neutral Switch (Automatic Transmission) - Vehicle Speed Sensor PCM Outputs: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 222 - Air Conditioning Clutch Relay - Air Conditioning WOT Relay - Auto Shutdown (ASD) Relay - Charging Indicator Lamp - Data Link Connector - Duty Cycle EVAP Canister Purge Solenoid - EGR Solenoid - Fuel Injectors - Fuel Pump Relay - Generator Field - Idle Air Control Motor - Ignition Coils - Malfunction Indicator (Check Engine) Lamp - Radiator Fan Relay - Speed Control Solenoids - Tachometer - Torque Convertor Clutch Solenoid Based on inputs it receives, the PCM adjusts: Fuel Injector Pulse Width - Idle Speed - Ignition Spark Advance - Ignition Coil Dwell - EVAP Canister Purge Operation. The PCM Regulates: Cooling Fan - Air Conditioning - Speed Control System - Generator Charge Rate -- by Adjusting The Generator Field The PCM Also Performs Diagnostics The PCM adjusts injector pulse width (air-fuel ratio) based on: Battery Voltage - Coolant Temperature - Exhaust Gas Content (Oxygen Sensor) - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Manifold Absolute Pressure - Throttle Position The PCM adjusts ignition timing based on: Coolant Temperature - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Knock Sensor - Manifold Absolute Pressure - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) The PCM also adjusts engine idle speed through the idle air control motor based on: Air Conditioning Sense - Battery Temperature - Battery Voltage - Brake Switch - Coolant Temperature - Engine Speed (crankshaft Position Sensor) - Engine Run Time - Manifold Absolute Pressure - Power Steering Pressure Switch - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) - Vehicle Distance (Speed) ASD and Fuel Pump Relay Control Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 223 The Auto Shutdown (ASD) and fuel pump relays are mounted externally, but turned on and off by the PCM. Crankshaft Position (Engine Speed) Signal The crankshaft position sensor signal is sent to the PCM. If the PCM does not receive the signal within approximately one second of engine cranking, it deactivates the ASD relay and fuel pump relay When these relays deactivate, power is shut off from the fuel injectors, ignition coils, heating element in the oxygen sensors and the fuel pump. PCM Regulated Output Supply Voltages The PCM contains a voltage converter that changes battery voltage to a regulated 8 volts direct current to power: Camshaft Position Sensor - Crankshaft Position Sensor - Vehicle Speed Sensor The PCM also provides a 5 volt direct current supply for: Manifold Absolute Pressure Sensor - Throttle Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 224 Powertrain Control Module: Description and Operation System Operation SYSTEM OPERATION Powertrain Control Module The speed control electronic control circuitry is integrated into the Powertrain Control Module (PCM). The PCM is located in the engine compartment. The PCM speed control functions are monitored by the On-Board Diagnostics (OBD). All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. The PCM cannot be repaired and must be replaced if faulty. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview Circuit A14 connects to a bus bar in the PDC that the battery feeds. Circuit A14 powers the Automatic Shut Down (ASD) relay and fuel pump relay The A14 circuit also splices to the data link connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Page 227 Powertrain Control Module: Service and Repair Fig. 100 Powertrain Control Module NOTE: The PCM attaches to the inner fender panel next to the washer fluid bottle on the driver side (Fig. 100). REMOVAL 1. Disconnect negative cable from battery 2. Disconnect positive cable from battery. 3. Remove washer bottle neck. 4. Squeeze tabs on Power Distribution Center (PDC) while pulling PDC up to remove it from bracket. - Lay PDC aside to gain access to PCM bracket screws. 5. Remove screws attaching PCM to body. 3. Lift PCM up and disconnect the 2 40-way connector 7. Remove PCM. INSTALLATION 1. Attach the 2 40-way connector to PCM. 2. Install PCM. Tighten mounting screws to 4 Nm (35 in lb) torque. 3. Install PDC by pushing down into brackets. 4. Install washer bottle neck. 5. Connect positive cable to battery. 6. Connect negative cable to battery. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig. 15 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 231 Power Distribution Center (Top) The relay is located in the Power Distribution Center (PDC). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector Auto Shutdown Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector > Page 234 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Power Distribution Center (Bottom) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector > Page 235 Power Distribution Center (Top) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 236 Automatic Shut Down (ASD) Relay: Description and Operation Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. CIRCUIT OPERATION The Automatic Shut Down (ASD) relay is located in the Power Distribution Center (PDC). Power for the coil and contact side of the relay is supplied on circuit A14. This circuit is HOT at all times and protected by a 20 Amp fuse located in the PDC. The Powertrain Control Module (PCM) controls the ground path for the coil side of the relay on circuit K51. This circuit connects to cavity 67 of the PCM. When the PCM supplies the ground path on circuit K51 the contacts in the relay CLOSE connecting circuits A14 and A142. The A142 circuit is spliced and supplies power to the generator, fuel injectors, PCM, ignition coil, and heated oxygen sensors. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 Amp fuse located in the PDC. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 239 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 240 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Component Locations Fuel Pump Relay: Component Locations Power Distribution Center (Top) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Component Locations > Page 246 Fig. 15 Power Distribution Center (PDC) The fuel pump relay is located in the Power Distribution Center (PDC). The inside top of the PDC cover has a label showing relay and fuse location. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Component Locations > Page 247 Fuel Pump Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Fuel Pump Relay Connector Fuel Pump Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Fuel Pump Relay Connector > Page 250 Fuel Pump Relay: Diagrams Power Distribution Power Distribution Center (Bottom) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Fuel Pump Relay Connector > Page 251 Power Distribution Center (Top) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Fuel Pump Relay Operation Fuel Pump Relay: Description and Operation Fuel Pump Relay Operation NAME OF CODE: Fuel Pump Relay Control Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the fuel pump relay control circuit. THEORY OF OPERATION: The fuel pump relay controls the 12-volt source to the fuel pump. If the vehicle is equipped with a power distribution center, the relay is located in the Power Distribution Center (PDC). One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the RUN or CRANK position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the fuel pump relay control circuit ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Fuel pump relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Fuel Pump Relay Operation > Page 254 Fuel Pump Relay: Description and Operation Fuel Pump Relay Control Circuit Trouble Code Name of Code: Fuel Pump Relay Control Circuit When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: An open or shorted condition is detected in the fuel pump relay control circuit. Theory of Operation: The fuel pump relay controls the 12-volt source to the fuel pump. If the vehicle is equipped with a power distribution center, the relay is located in the PDC. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "run position". The circuit is completed when the other side of the relay coil is grounded by the powertrain control module. The PCM grounds the relay when the ignition switch is in either the run or crank position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the fuel pump relay control circuit ground. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - Fuel pump relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Page 255 Fuel Pump Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30 is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85 -- The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86 supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A -- When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87 When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Page 256 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig. 15 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 260 Power Distribution Center (Top) The relay is located in the Power Distribution Center (PDC). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector Auto Shutdown Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector > Page 263 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Power Distribution Center (Bottom) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector > Page 264 Power Distribution Center (Top) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 265 Automatic Shut Down (ASD) Relay: Description and Operation Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. CIRCUIT OPERATION The Automatic Shut Down (ASD) relay is located in the Power Distribution Center (PDC). Power for the coil and contact side of the relay is supplied on circuit A14. This circuit is HOT at all times and protected by a 20 Amp fuse located in the PDC. The Powertrain Control Module (PCM) controls the ground path for the coil side of the relay on circuit K51. This circuit connects to cavity 67 of the PCM. When the PCM supplies the ground path on circuit K51 the contacts in the relay CLOSE connecting circuits A14 and A142. The A142 circuit is spliced and supplies power to the generator, fuel injectors, PCM, ignition coil, and heated oxygen sensors. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 Amp fuse located in the PDC. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 268 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 269 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module Technical Service Bulletin # 731 Date: 970701 Recall - Airbag Control Module No. 731 July, 1997 To: All Dealers Subject: Safety Recall # 731 -- Airbag Control Module Models: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. To correct this condition, the airbag control module (ACM) must be replaced. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for service as determined by using DIAL System Function 70. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53, 70 and VIP All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time of recall implementation for dealer inquiry as needed. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 279 Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough of each ACM Package to service about 25% of those vehicles. Each package contains one (1) ACM. Refer to the table above for the appropriate package application: Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Service Procedure For Neon (PL) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. For Manual Transmission Equipped Vehicles: Remove the shifter knob fastener and remove the shifter knob. 3. Remove the front two (2) center console attaching screws located near the cup holders (Figure 1). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 280 4. Remove the two (2) screws at the bottom of the storage bin (Figure 2). 5. Remove the bolt access covers and the two lower console bracket bolts on each side of the console bin. 6. Raise the park brake hand lever as high as possible. 7. Remove the center console assembly. WARNING: The auto adjusting feature of the park brake lever assembly contains a clock spring loaded to approximately 20 lbs. DO NOT release the auto adjuster lock out device before installing the cables into the equalizer. Keep hands out of auto adjuster sector and pawl area. Failure to observe caution in handling this mechanism could lead to serious injury. 8. Lower the park brake handle. 9. Grasp the park brake lever output cable by hand and pull upward until a 3/16" drill bit can be inserted into the handle and sector gear mechanism (Figure 3). This will remove the tension from the park brake cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 281 10. Remove both rear park brake cables from the park brake cable equalizer (Figure 4). 11. Disconnect the brake warning light electrical connector from the park brake lever switch. 12. Remove the two park brake lever attaching nuts and remove the park brake lever assembly. 13. Disconnect the ACM wiring connector (Figure 5): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 14. Remove the remaining three (3) nuts that secure the ACM mounting bracket to the floor, disconnect the two (2) park brake lever switch wire harness clips from the ACM bracket and then remove the ACM and bracket assembly. 15. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 16. Loosely install the three (3) ACM attaching nuts. 17. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 282 18. Install the park brake lever assembly. 19. Tighten the four (4) ACM nuts and the remaining park brake lever nut to 115 in-lbs (12.5 N.m). 20. Connect the park brake lever switch electrical connector and attach the wiring clips to the ACM bracket. 21. Install both rear park brake cables into the equalizer. 22. Pull the park brake lever handle all the way up. 23. Firmly grasp the park brake lever locking pin (drill bit) and quickly remove it from the mechanism. 24. Cycle the park brake lever once to position the park brake cables. 25. Make sure that the park brake lever is fully raised and then install the center console assembly. 26. Install the front two (2) center console attaching screws located near the cup holders (Figure 1). 27. Install the two (2) screws at the bottom of the storage bin (Figure 2). 28. Install the two (2) outer lower console bracket bolts on each side of the storage bin and then install the bolt covers. 29. For Manual Transmission Equipped Vehicles: Install the shifter knob and fastener. 30. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 31. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 32. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Dakota (AN) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area around the center instrument panel support. 3. Remove the two (2) front center support bracket screws (Figure 6). 4. Remove the two (2) left side and one (1) right side support bracket screws (Figure 6). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 283 5. Remove the support bracket. 6. Remove the ground eyelet screw from the left side of the ACM bracket. 7. Disconnect the ACM wiring connector (Figure 7): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 8. Remove the three (3) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 8). 9. Remove the ACM and bracket assembly. 10. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 11. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 105 in-lbs (11.8 N.m). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 284 12. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 13. Install the ground eyelet screw to the left side of the ACM bracket. 14. Install the center instrument panel support bracket. 15. Install the two (2) left side and one (1) right side support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 16. Install the two (2) front center support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 17. Reinstall the floor carpet around the center instrument panel support. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Wrangler (TJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area under the heater-A/C housing floor duct and forward of the center floor console. 3. For vehicles equipped with ABS: Remove the ABS acceleration sensor from its mounting bracket and set aside (Figure 9). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 285 4. Remove the four (4) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 10). 5. Disconnect the ACM wiring connector (Figure 11): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 6. Slide the ACM and bracket assembly out from under the heater-A/C housing floor duct and remove it from the vehicle. 7. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 8. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 9. Tighten the four (4) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m) (Figure 10). 10. For vehicles equipped with ABS: Reinstall the ABS acceleration sensor (Figure 9). Tighten the sensor mounting bolts to 40 in-lbs (4.5 N.m). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 286 11. Reinstall the floor carpet under the heater-A/C floor duct. 12. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 13. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 14. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Grand Cherokee (ZJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the transmission shift lever handle by pulling straight up firmly and quickly. 3. Pry up the transmission shift indicator bezel with a trim stick (Figure 12). 4. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transmission shift indicator bezel from the console. 5. Pry up the transfer case shift indicator bezel with a trim stick (Figure 12). 6. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transfer case bezel from the console. 7. Remove the console attaching screws and then remove the console (Figure 12). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 287 8. Disconnect the ACM wiring connector (Figure 13): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 9. Remove the four (4) screws that secure the ACM mounting bracket to the floor transmission tunnel (Figure 14). 10. Remove the ACM and bracket assembly. 11. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 12. Tighten the four (4) ACM attaching screws to 95 in-lbs (10.7 N.m). 13. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 14. Install the console and secure it with the attaching screws (Figure 12). 15. Install the lamp socket into the transfer case shift bezel and then install the bezel into the console (Figure 12). 16. Install the lamp socket into the transmission shift indicator bezel and then install the bezel into the console (Figure 12). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 288 17. Install the transmission shift lever handle. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Viper GTS Coupe (SR) Vehicles: 1. Remove the left rear wheel and tire assembly. 2. Remove the left rear wheel well inner splash shield. 3. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 4. Remove the instrument panel center bezel and then disconnect the rear window defogger switch, the power window switches and the lighter (Figure 15). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 289 5. Remove the right and left knee blockers (Figure 16). 6. Remove the headlamp switch knob by inserting a paper clip in the hole under the knob and pushing gently to release the lock clip (Figure 16). 7. Remove the tilt steering handle. 8. Remove the upper steering column shroud. 9. Remove the instrument panel bezel (Figure 16). NOTE: Be careful not to break the headlamp switch lock tab when removing the I/P bezel. 10. Remove the two (2) radio mounting screws. 11. Remove the radio and disconnect the wire connector, coaxial cable and antenna cable. 12. Remove the radio from the vehicle. 13. Remove the HVAC control module. Only disconnect the vacuum and electrical connectors. Do not disconnect the cable. Set the control module aside. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 290 14. Reach through the radio opening and disconnect the ACM wiring connector (Figure 17): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 15. Remove the three (3) nuts that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 18). 16. Slide the ACM and bracket assembly out through the radio opening. 17. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 18. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m). 19. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 20. Connect the HVAC control head electrical and vacuum connectors. Install the HVAC control module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 291 21. Connect the radio wire connector, coaxial cable and antenna cable. 22. Install the radio into the instrument panel and tighten the two (2) mounting screws. 23. Install the instrument panel bezel (Figure 16). NOTE: Be careful when installing the I/P bezel. Do not break the headlamp switch lock tab. 24. Install the headlamp switch knob (Figure 16). 25. Install the upper steering column cover. 26. Install the tilt steering handle. 27. Install the right and left knee blockers (Figure 16). 28. Connect the rear window defogger switch, the power window switches and the lighter and then install the instrument panel center bezel (Figure 15). 29. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 30. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 31. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. 32. Install the left rear wheel well inner splash shield. 33. Install the left rear wheel and tire assembly. Completion Reporting and Reimbursement / Parts Return Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. Parts Return Initially, a small number of ACM and bracket assemblies are required to be returned to the Warranty Material Return Center. When an adequate number of returned parts have been accumulated, Parts Return Documents will no longer be generated and parts are to be discarded. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 292 CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dealer Service Instructions IMPORTANT Safety Recall # 731 -- Airbag Control Module ^ Effective immediately, this recall (# 731) cancels and supercedes Recall # 683 -- Airbag Control Module for 1997 Jeep Wrangler (TJ) vehicles. ^ This service requirement applies only to: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) ^ The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position. To correct this condition, the airbag control module (ACM) must be replaced. Parts Packages: ^ Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough ACM Packages to service about 25% of those vehicles. Owner Letter SAFETY RECALL TO REPLACE YOUR VEHICLE'S AIRBAG CONTROL MODULE Dear Chrysler Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1997 Plymouth and Dodge Neon; Dodge Dakota; Jeep Grand Cherokee and Wrangler; and 1996 Dodge Viper GTS Coupe vehicles. The problem is... The airbags on your vehicle (identified on the enclosed form), may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. What Chrysler and your dealer will do... Chrysler will repair your (vehicle) free of charge (parts and labor). To do this, your dealer will replace the airbag control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 293 If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module Technical Service Bulletin # 731 Date: 970701 Recall - Airbag Control Module No. 731 July, 1997 To: All Dealers Subject: Safety Recall # 731 -- Airbag Control Module Models: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. To correct this condition, the airbag control module (ACM) must be replaced. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for service as determined by using DIAL System Function 70. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53, 70 and VIP All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time of recall implementation for dealer inquiry as needed. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 299 Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough of each ACM Package to service about 25% of those vehicles. Each package contains one (1) ACM. Refer to the table above for the appropriate package application: Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Service Procedure For Neon (PL) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. For Manual Transmission Equipped Vehicles: Remove the shifter knob fastener and remove the shifter knob. 3. Remove the front two (2) center console attaching screws located near the cup holders (Figure 1). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 300 4. Remove the two (2) screws at the bottom of the storage bin (Figure 2). 5. Remove the bolt access covers and the two lower console bracket bolts on each side of the console bin. 6. Raise the park brake hand lever as high as possible. 7. Remove the center console assembly. WARNING: The auto adjusting feature of the park brake lever assembly contains a clock spring loaded to approximately 20 lbs. DO NOT release the auto adjuster lock out device before installing the cables into the equalizer. Keep hands out of auto adjuster sector and pawl area. Failure to observe caution in handling this mechanism could lead to serious injury. 8. Lower the park brake handle. 9. Grasp the park brake lever output cable by hand and pull upward until a 3/16" drill bit can be inserted into the handle and sector gear mechanism (Figure 3). This will remove the tension from the park brake cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 301 10. Remove both rear park brake cables from the park brake cable equalizer (Figure 4). 11. Disconnect the brake warning light electrical connector from the park brake lever switch. 12. Remove the two park brake lever attaching nuts and remove the park brake lever assembly. 13. Disconnect the ACM wiring connector (Figure 5): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 14. Remove the remaining three (3) nuts that secure the ACM mounting bracket to the floor, disconnect the two (2) park brake lever switch wire harness clips from the ACM bracket and then remove the ACM and bracket assembly. 15. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 16. Loosely install the three (3) ACM attaching nuts. 17. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 302 18. Install the park brake lever assembly. 19. Tighten the four (4) ACM nuts and the remaining park brake lever nut to 115 in-lbs (12.5 N.m). 20. Connect the park brake lever switch electrical connector and attach the wiring clips to the ACM bracket. 21. Install both rear park brake cables into the equalizer. 22. Pull the park brake lever handle all the way up. 23. Firmly grasp the park brake lever locking pin (drill bit) and quickly remove it from the mechanism. 24. Cycle the park brake lever once to position the park brake cables. 25. Make sure that the park brake lever is fully raised and then install the center console assembly. 26. Install the front two (2) center console attaching screws located near the cup holders (Figure 1). 27. Install the two (2) screws at the bottom of the storage bin (Figure 2). 28. Install the two (2) outer lower console bracket bolts on each side of the storage bin and then install the bolt covers. 29. For Manual Transmission Equipped Vehicles: Install the shifter knob and fastener. 30. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 31. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 32. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Dakota (AN) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area around the center instrument panel support. 3. Remove the two (2) front center support bracket screws (Figure 6). 4. Remove the two (2) left side and one (1) right side support bracket screws (Figure 6). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 303 5. Remove the support bracket. 6. Remove the ground eyelet screw from the left side of the ACM bracket. 7. Disconnect the ACM wiring connector (Figure 7): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 8. Remove the three (3) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 8). 9. Remove the ACM and bracket assembly. 10. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 11. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 105 in-lbs (11.8 N.m). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 304 12. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 13. Install the ground eyelet screw to the left side of the ACM bracket. 14. Install the center instrument panel support bracket. 15. Install the two (2) left side and one (1) right side support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 16. Install the two (2) front center support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 17. Reinstall the floor carpet around the center instrument panel support. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Wrangler (TJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area under the heater-A/C housing floor duct and forward of the center floor console. 3. For vehicles equipped with ABS: Remove the ABS acceleration sensor from its mounting bracket and set aside (Figure 9). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 305 4. Remove the four (4) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 10). 5. Disconnect the ACM wiring connector (Figure 11): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 6. Slide the ACM and bracket assembly out from under the heater-A/C housing floor duct and remove it from the vehicle. 7. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 8. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 9. Tighten the four (4) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m) (Figure 10). 10. For vehicles equipped with ABS: Reinstall the ABS acceleration sensor (Figure 9). Tighten the sensor mounting bolts to 40 in-lbs (4.5 N.m). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 306 11. Reinstall the floor carpet under the heater-A/C floor duct. 12. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 13. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 14. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Grand Cherokee (ZJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the transmission shift lever handle by pulling straight up firmly and quickly. 3. Pry up the transmission shift indicator bezel with a trim stick (Figure 12). 4. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transmission shift indicator bezel from the console. 5. Pry up the transfer case shift indicator bezel with a trim stick (Figure 12). 6. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transfer case bezel from the console. 7. Remove the console attaching screws and then remove the console (Figure 12). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 307 8. Disconnect the ACM wiring connector (Figure 13): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 9. Remove the four (4) screws that secure the ACM mounting bracket to the floor transmission tunnel (Figure 14). 10. Remove the ACM and bracket assembly. 11. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 12. Tighten the four (4) ACM attaching screws to 95 in-lbs (10.7 N.m). 13. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 14. Install the console and secure it with the attaching screws (Figure 12). 15. Install the lamp socket into the transfer case shift bezel and then install the bezel into the console (Figure 12). 16. Install the lamp socket into the transmission shift indicator bezel and then install the bezel into the console (Figure 12). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 308 17. Install the transmission shift lever handle. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Viper GTS Coupe (SR) Vehicles: 1. Remove the left rear wheel and tire assembly. 2. Remove the left rear wheel well inner splash shield. 3. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 4. Remove the instrument panel center bezel and then disconnect the rear window defogger switch, the power window switches and the lighter (Figure 15). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 309 5. Remove the right and left knee blockers (Figure 16). 6. Remove the headlamp switch knob by inserting a paper clip in the hole under the knob and pushing gently to release the lock clip (Figure 16). 7. Remove the tilt steering handle. 8. Remove the upper steering column shroud. 9. Remove the instrument panel bezel (Figure 16). NOTE: Be careful not to break the headlamp switch lock tab when removing the I/P bezel. 10. Remove the two (2) radio mounting screws. 11. Remove the radio and disconnect the wire connector, coaxial cable and antenna cable. 12. Remove the radio from the vehicle. 13. Remove the HVAC control module. Only disconnect the vacuum and electrical connectors. Do not disconnect the cable. Set the control module aside. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 310 14. Reach through the radio opening and disconnect the ACM wiring connector (Figure 17): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 15. Remove the three (3) nuts that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 18). 16. Slide the ACM and bracket assembly out through the radio opening. 17. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 18. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m). 19. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 20. Connect the HVAC control head electrical and vacuum connectors. Install the HVAC control module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 311 21. Connect the radio wire connector, coaxial cable and antenna cable. 22. Install the radio into the instrument panel and tighten the two (2) mounting screws. 23. Install the instrument panel bezel (Figure 16). NOTE: Be careful when installing the I/P bezel. Do not break the headlamp switch lock tab. 24. Install the headlamp switch knob (Figure 16). 25. Install the upper steering column cover. 26. Install the tilt steering handle. 27. Install the right and left knee blockers (Figure 16). 28. Connect the rear window defogger switch, the power window switches and the lighter and then install the instrument panel center bezel (Figure 15). 29. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 30. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 31. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. 32. Install the left rear wheel well inner splash shield. 33. Install the left rear wheel and tire assembly. Completion Reporting and Reimbursement / Parts Return Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. Parts Return Initially, a small number of ACM and bracket assemblies are required to be returned to the Warranty Material Return Center. When an adequate number of returned parts have been accumulated, Parts Return Documents will no longer be generated and parts are to be discarded. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 312 CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dealer Service Instructions IMPORTANT Safety Recall # 731 -- Airbag Control Module ^ Effective immediately, this recall (# 731) cancels and supercedes Recall # 683 -- Airbag Control Module for 1997 Jeep Wrangler (TJ) vehicles. ^ This service requirement applies only to: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) ^ The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position. To correct this condition, the airbag control module (ACM) must be replaced. Parts Packages: ^ Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough ACM Packages to service about 25% of those vehicles. Owner Letter SAFETY RECALL TO REPLACE YOUR VEHICLE'S AIRBAG CONTROL MODULE Dear Chrysler Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1997 Plymouth and Dodge Neon; Dodge Dakota; Jeep Grand Cherokee and Wrangler; and 1996 Dodge Viper GTS Coupe vehicles. The problem is... The airbags on your vehicle (identified on the enclosed form), may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. What Chrysler and your dealer will do... Chrysler will repair your (vehicle) free of charge (parts and labor). To do this, your dealer will replace the airbag control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 313 If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 314 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 315 Connector Pin-Outs Component Index Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 316 Air Bag Control Module: Service Precautions Electrical Precautions Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 317 Air Bag Control Module: Description and Operation SYSTEM OPERATION Airbag Control Module Location The Airbag Control Module (ACM) contains the safing sensor and energy reserve capacitor. The safing sensor is located inside the ACM. The module is mounted on the tunnel/floor pan between the gear shift lever and the park brake lever. The safing sensor provides confirmation of a crash, but does not discriminate severity. The ACM monitors the system to determine the system readiness. The ACM contains on-board diagnostics, and will illuminate the AIRBAG warning lamp in the cluster when a fault occurs. The warning equipment is tested for 6 to 8 Seconds every time the vehicle is started. Driver And Passenger Airbag Module WARNING: NEVER DISASSEMBLE THE DRIVER OR PASSENGER AIRBAG MODULE, THERE ARE NO SERVICEABLE PARTS WITH IN THE MODULES. Driver Airbag The Driver Airbag Module located on the steering wheel is the most visible part of the system. The airbag module contains a housing to which the cushion, inflator and cover are attached to. The driver side inflator assembly is mounted from the back of the module housing. When supplied with the proper electrical signal the inflator assembly will produce a gas and discharge it directly into the cushion. A protective cover is fitted to the front of the Driver Airbag Module and forms a decorative cover in the center of the steering wheel. The Driver Airbag Module is mounted directly to the steering wheel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 318 Passengers Airbag The Passenger Airbag Module is located beneath the decorative cover of the instrument panel, facing the passenger seat. The passenger inflator assembly is within the module housing. The module is mounted to the instrument panel retainer and support structure. When supplied with the proper electrical signal the inflator will produce a gas and discharge it directly into the cushion. A protective cover is fitted into the instrument panel over the airbag module and forms a decorative cover. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 319 Air Bag Control Module: Service and Repair REMOVAL WARNING: - THE ACM CONTAINS A SAFING SENSOR WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT THE ACM ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. - DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION PROCEDURE. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR 2 MINUTES BEFORE REMOVING ANY AIRBAG COMPONENTS. CAUTION: Failure to follow the parking brake service procedures can result in damage to the parking brake mechanism. 1. Disconnect and isolate the battery negative cable. 2. Manual transaxle only, remove shifter knob fastener and remove shifter knob. Attaching Screws At Rear Of Center Console With/Without Arm Rest Attaching Screws At Rear Of Center Console With Arm Rest 3. Remove screws attaching rear of center console assembly to console bracket. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 320 Attaching Screws At Front Of Center Console 4. Remove the two screws located in cup holders, attaching front of center console assembly to console bracket. 5. Raise park brake hand lever assembly as high as it will go for required clearance to remove center console. 6. Remove center console assembly from vehicle. WARNING: THE AUTO ADJUSTING FEATURE OF THIS PARKING BRAKE LEVER ASSEMBLY CONTAINS A CLOCK SPRING LOADED TO APPROXIMATELY 20 POUNDS. DO NOT RELEASE THE AUTO ADJUSTER LOCKOUT DEVICE BEFORE INSTALLING CABLES INTO THE EQUALIZER. KEEP HANDS OUT OF AUTO ADJUSTER SECTOR AND PAWL AREA. FAILURE TO OBSERVE CAUTION IN HANDLING THIS MECHANISM COULD LEAD TO SERIOUS INJURY. WHEN REPAIRS TO THE PARK BRAKE HAND LEVER ASSEMBLY OR CABLES IS REQUIRED, THE AUTO ADJUSTER MUST BE RELOADED AND LOCKED OUT. 7. Lower park brake lever handle. Locking Pin Installed In Park Brake Mechanism 8. Grasp park brake lever output cable by hand and pull upward. Continue pulling on cable until a 3/16 in. drill bit can be inserted into handle and sector gear of park brake mechanism. This will lock the park brake mechanism and take tension off park brake cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 321 Locking Pin Installed In Park Brake Mechanism 9. Remove both rear park brake cables from the park brake cable equalizer. Brake Warning Lamp Connection To Park Brake Lever 10. Remove wiring harness electrical connector for brake warning light from park brake lever. Park Brake Lever Attachment To Console Bracket 11. Remove the two nuts attaching park brake lever to console bracket. Remove park brake lever mechanism from vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 322 Airbag Control Module 12. Remove module mounting nuts and remove module. ACM Connector 13. Disconnect ACM 23-PIN connector. 14. Remove Airbag Control Module. INSTALLATION 1. Connect ACM connector and ensure that the connector locking tab is engaged. CAUTION: USE SUPPLIED SCREWS ONLY 2. Position ACM (arrow pointing forward) in the console floor bracket, attach the nuts and tighten to 11 to 14 N.m (105 to 125 in. lbs.) torque. NOTE: The park brake lever can be in any position when releasing the auto adjuster. To ease installation of center console, it is advisable to pull park brake lever handle all the way up before removing lockout pin. 3. Place park brake lever on console bracket. Install and securely tighten the 2 attaching nuts. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 323 Park Brake Cables Properly Installed In Equalizer Rear Park Brake Cable Installation On Equalizer 4. Install both rear park brake cables into equalizer on park brake lever output cable. 5. Ensure that park brake cable is correctly installed and aligned with cable track on park brake lever. 6. Pull park brake lever handle all the way up. Removing Lockout Pin From Park Brake Lever Assembly 7. Firmly grasp park brake lever locking pin and quickly remove it from the park brake lever mechanism, This will allow the park brake lever mechanism to correctly adjust the park brake cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 324 Brake Warning Lamp Connection To Park Brake Lever 8. Connect electrical connector for brake warning lamp onto terminal on park brake lever assembly. 9. Cycle park brake lever once to position park brake cables. Then return the park brake lever its released position. Check the rear wheels of the vehicle. They should rotate freely without dragging. 10. Raise park brake lever to its fully engaged position. This is necessary to allow installation of the center console. 11. Install center console assembly. Attaching Screws At Rear Of Center Console With/Without Arm Rest Attaching Screws At Rear Of Center Console With Arm Rest Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 325 Attaching Screws At Front Of Center Console 12. Install the four center console assembly attaching screws. 13. Replace shifter knob and fastener. 14. Do not connect battery negative cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Component Locations Power Distribution Center (Top) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Component Locations > Page 331 Auto Shutdown Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 332 Starter Relay: Diagrams Power Distribution Center (Bottom) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 333 Power Distribution Center (Top) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 334 Starter Relay: Testing and Inspection WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK POSITION/NEUTRAL WITH THE PARKING BRAKE APPLIED Relay Test The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. Remove the starter relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 Ohms. If OK, go to Step 3. If not OK, replace the faulty relay 3. Connect a battery B+ lead to terminals 86 and a ground lead to terminal 85 to energize the relay The relay should click. Also test for continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, refer to Relay Circuit Test procedure. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. It is energized when the ignition switch is held in the Start position. On vehicles with a manual transmission, the clutch pedal must be fully depressed for this test. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position, and no voltage when the ignition switch is released to the On position. If OK, go to Step 5. If not OK with an automatic transmission, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, see the Ignition Switch Test procedure. If not OK with a manual transmission, check the circuit between the relay and the clutch pedal position switch for an open or a short. If the circuit is OK, see the Clutch Pedal Position Switch/Brake pedal Switch/Sensor Test procedure. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with an automatic transmission, it is grounded through the park/neutral position switch only when the gearshift selector lever is in the Park or Neutral positions. On vehicles with a manual transmission, it is grounded at all times. Check for continuity to ground at the cavity for relay terminal 85. If not OK with an automatic transmission, check for an open or short circuit to the park/neutral position switch and repair, if required. If the circuit is OK, see the Park/Neutral Position Switch/Neutral Safety Switch Test procedure. If not OK with a manual transmission, repair the circuit to ground as required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation Power Door Lock Switch: Description and Operation CIRCUIT OPERATION Left Door Switch Operation (Lock) When the door lock switch is moved to the LOCK position, voltage is supplied on the P35 circuit to the bus bar located inside the right door switch, lock side. Battery voltage is passed through the switch to the P33 circuit to the door motors. Grounding is provided through the P34 circuit for all door motors back to the right door switch. The ground is passed through the bus bar internal to the switch, UNLOCK side, to the P36 circuit. The P36 circuit connects to the left front switch to a bus bar, internal to the switch, and then to the Z8 circuit. The Z8 circuit connects to its grounding point. Left Door Switch Operation (Unlock) When the switch is moved to the UNLOCK position, voltage is supplied on the P36 circuit to the right door switch, unlock side. The battery voltage is passed through the switch internal bus bar to the P34 circuit. The P34 circuit then connects to the door motors on the unlock side. Grounding for the UNLOCK function is provided by the P33 circuit. The P33 circuit connects back to the right door switch, LOCK side, and passes through the internal bus bar to the P35 circuit. The P35 circuit connects back to the left door switch, and passes through the switch to the Z8 circuit. The Z8 circuit goes to it's grounding point. Right Door Switch Operation (Lock) When the switch is moved to the LOCK position, voltage is supplied to the P33 circuit, and then to the door lock motors. The ground path is provided on the P34 circuit back to the right door switch. The ground is passed through the switch internal bus bar to the P36 circuit. The P36 circuit connects to the left door switch and through to the Z8 circuit. The Z8 circuit then connects to the grounding point at the left center instrument panel support. Right Door Switch Operation (Unlock) When the switch is moved to the UNLOCK position voltage is supplied to the P34 circuit from the switch to the door UNLOCK side of the motors. The grounding path is through the LOCK side of the motors, circuit P33, back to the switch. The ground continues through the internal bus bar of the switch on circuit P35 to the left door switch. At the left door switch, the ground passes through that switches internal bus bar to the Z8 grounding point. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Page 345 Power Door Lock Switch: Testing and Inspection Door Lock Switch Continuity Test Remove the switch from its mounting location. Using an ohmmeter, refer to the Door Lock Switch Continuity Test to determine if continuity is correct in the Lock and Unlock switch positions. If these results are not obtained, replace the switch. Wiring The following wiring test sequence determines whether or not voltage is continuous through the body harness to switch. 1. Remove left side switch from door trim panel. 2. Carefully separate multiple terminal block on wiring harness from switch body. 3. Connect one lead of test light to a ground terminal. Touch other test light lead to Red Wire terminal. a. If test light comes on, the wiring circuit between the battery and switch is functional. b. If test light does not come on, check fuse 3 in the fuse block or for a open circuit. 4. If test light comes on, the wiring circuit between the battery and switch is functional. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Page 346 Power Door Lock Switch: Service and Repair REMOVAL 1. Remove front door trim. 2. Disconnect wire connector. 3. Remove attaching screws. 4. Remove the switch. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation Power Mirror Switch: Description and Operation CIRCUIT OPERATION The power mirror switch has a right and left position. Moving the switch to either of these positions changes the voltage path internal to the switch (i.e.. changes polarity at the motors). When the switch is moved to the left position and mirror movement UP is selected, voltage is supplied through the P93 circuit and the ground path is through circuit P90. When the DOWN movement is selected the power and ground are reversed. If a left door mirror movement LEFT is selected voltage is supplied through the P95 circuit and the ground is passed through circuit P91. When the left door minor RIGHT movement is selected the power and ground are reversed. When the switch is moved to the right position and mirror movement UP is selected, voltage is supplied through the P92 circuit and the ground path is through circuit P90. When the DOWN movement is selected the power and ground are reversed. If a right door mirror movement LEFT is selected voltage is supplied through the P94 circuit and the ground is passed through circuit P91. When the left door mirror RIGHT movement is selected the power and ground are reversed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 350 Power Mirror Switch: Testing and Inspection Mirror Switch Test Mirror Switch Test 1. Remove power mirror switch from mounting position. 2. Disconnect wiring harness at switch connector. 3. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror Switch Test and RHD Power Fold Away Mirror Switch Test. 4. If test results are not obtained as shown, replace the switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 351 Power Mirror Switch: Service and Repair REMOVAL 1. Remove door trim panel. 2. Remove switch mounting screws from back side of trim panel and remove switch. 3. Disconnect wire connector. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Switch <--> [Brake Fluid Level Sensor/Switch] > Component Information > Locations Master Cylinder Fluid Level Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Switch <--> [Brake Fluid Level Sensor/Switch] > Component Information > Locations > Page 356 Brake Fluid Level Switch: Service and Repair GENERAL INFORMATION The master cylinder or brake fluid reservoir does not have to be removed from vehicle for replacement of the brake fluid level sensor. Master Cylinder Fluid Level Sensor 1. Remove wiring harness connector from brake fluid reservoir level sensor. Brake Fluid Level Switch Retaining Tabs 2. Compress retaining tabs on end of brake fluid level switch. Removing/Installing Fluid Reservoir Level Switch 3. While compressing retaining tabs, grasp opposite end of brake fluid level switch and pull it out of master cylinder brake fluid reservoir. 4. Correctly align the replacement level switch with its mounting hole in the brake fluid reservoir. Push switch into fluid reservoir until retaining tabs are fully expanded on opposite side of fluid reservoir. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Switch <--> [Brake Fluid Level Sensor/Switch] > Component Information > Locations > Page 357 5. Install the wiring harness connector onto the brake fluid level switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Description and Operation Braking Sensor/Switch: Description and Operation CIRCUIT OPERATION Circuit L50 is an input to the Controller Anti Lock Brake (CAB). The L50 connects to cavity 13 of the CAB connector. Circuit L50 is spliced in with the stop lamps and is used to provide the CAB with information on when the brakes are being applied. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 365 39 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 366 43 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 367 45 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 368 47 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 369 51 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 370 55 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 371 57 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 372 59 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 373 63 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 374 67 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 375 69 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 376 71 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 377 173 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 378 177 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 379 179 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 380 181 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 381 187 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 382 191 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 383 193 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 384 195 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 385 201 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 386 205 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 387 207 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 388 209 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 389 256 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 390 Wheel Speed Sensor: Specifications Front Rear Clearance Minimum Clearance 0.014 in 0.016 in Maximum Clearance 0.047 in 0.047 in Runout 0.006 in 0.006 in Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 391 Wheel Speed Sensor: Service Precautions NOTE: Proper installation of the Wheel Speed Sensor Cables is critical to continued system operation. Be sure that cables are installed, routed and clipped properly. Failure to install speed sensor cables as in the on car service section of this manual, may result in contact with moving parts or over extension of cables, resulting in an open circuit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation Wheel Speed Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION There are four wheel speed sensors, one at each wheel. The sensors use a tone wheel to determine wheel speed. Input to the Controller Anti Lock Brake (CAB) is done on the following circuits. All of these circuits are a twisted pair. B8 and B9 for the left front wheel (cavity 8 and cavity 9). B6 and B7 for the right front wheel (cavity 6 and cavity 7). B3 and B4 for the left rear wheel (cavity 3 and cavity 4). B1 and B2 for the right rear wheel (cavity 1 and cavity 2). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 394 Wheel Speed Sensor: Description and Operation Wheel Speed Sensors and Tone Wheels Front Wheel Speed Sensor Rear Wheel Speed Sensor With Drum Brakes Rear Wheel Speed Sensor With Rear Disc Brakes One Wheel Speed Sensor (WSS) is located at each wheel and sends a small AC signal to the Controller Antilock Brake (CAB). This signal is generated by magnetic induction created when a toothed sensor ring (tone wheel) passes the stationary magnetic Wheel Speed Sensor. The CAB converts the AC signal generated at each wheel into a digital signal. If a wheel locking tendency is detected by the CAB, it will then modulate hydraulic pressure via the Hydraulic Control Unit (HCU) to prevent the wheel(s) from locking. The front Wheel Speed Sensor is attached to a boss in the steering knuckle. The tone wheel is part of the outboard constant velocity joint. The rear Wheel Speed Sensor on rear drum brake applications is mounted to the rear brake support plate and the rear tone wheel is an integral part of the rear wheel hub and bearing assembly. The rear Wheel Speed Sensor on rear disc brake applications is mounted to the rear disc brake adapter and the rear tone wheel is also an integral part of the rearwheel hub and bearing assembly. The speed sensor air gap on both applications is NOT adjustable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 395 The four Wheel Speed Sensors are serviced individually. The front Tone Wheels are serviced as an assembly with the outboard constant velocity joint. The rear Tone Wheels are serviced as an assembly with the rear hub and bearing assembly. Correct ABS system operation is dependent on accurate wheel speed signals. The vehicle's wheels and tires must all be the same size and type to generate accurate signals. Variations in wheel and tire size can produce inaccurate wheel speed signals. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Page 396 Wheel Speed Sensor: Testing and Inspection CAREFUL INSPECTION Carefully inspect tone wheel at the suspected faulty wheel speed sensor for missing, chipped or broken teeth, this can cause erratic speed sensor signals. Tone wheels should show no evidence of contact with the wheel speed sensors. If contact was made, determine cause and correct before replacing the wheel speed sensor. Excessive Runout - of the tonewheel can cause erratic wheel speed sensor signals. Refer to Tone-wheel Runout under Specification. Replace drive shaft assembly or rear hub/bearing assembly if tonewheel runout exceeds the specification. Inspect For Looseness - on their mounting surfaces. Tone wheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Check the wheel speed sensor head alignment to the tone wheel. Also check the gap between the speed sensor head and the tone wheel to ensure it is at specification. See: Specifications Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front Speed Sensor Cable To Wiring Herness Connection Front Wheel Speed Sensor Attaching Bolt Front Wheel Speed Sensor Cable Routing NOTE: Proper installation of the Wheel Speed Sensor Cables is critical to continued system operation. Be sure that cables are installed, routed and clipped properly. Failure to install speed sensor cables as in the on car service section of this manual, may result in contact with moving parts or over extension of cables, resulting in an open circuit. REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. 3. Unplug speed sensor cable connector from vehicle wiring harness. Remove clip attaching speed sensor cable connector to vehicle body. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 399 4. Remove wheel speed sensor head to steering knuckle attaching bolt. 5. Carefully, remove sensor head from steering knuckle. If the sensor has seized, due to corrosion, DO NOT USE PLIERS ON SENSOR HEAD. Use a hammer and a punch and tap edge of sensor ear, rocking the sensor side to side until free. 6. Remove the speed sensor cable assembly grommets from the retaining bracket. Remove speed sensor cable routing clip from the frame of the vehicle. INSTALL 1. Connect the wheel speed sensor cable connector to the vehicle wiring harness. 2. Install the speed sensor cable assembly grommets into the retaining bracket. Install speed sensor cable routing clip onto the frame of the vehicle. 3. Install wheel speed sensor to steering knuckle attaching screw. Torque the attaching screw to 7 Nm (60 inch lbs.) 4. Install the wheel and tire assembly on vehicle. 5. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 400 Wheel Speed Sensor: Service and Repair Rear Rear Speed Sensor Connection To Vehicle Wiring Harness Speed Sensor Head Mounting And Cable Routing NOTE: Proper installation of the Wheel Speed Sensor Cables is critical to continued system operation. Be sure that cables are installed, routed and clipped properly. Failure to install speed sensor cables as in the on car service section of this manual, may result in contact with moving parts or over extension of cables, resulting in an open circuit. REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. 3. Unplug speed sensor cable connector from vehicle wiring harness. Remove clip attaching speed sensor cable connector to vehicle body. 4. Remove the speed sensor cable routing bracket from under rear brake flex hose mounting bracket. Then remove the speed sensor cable from the routing clips on the rear brake flex hose and chassis brake tube. 5. Remove bolt attaching the rear wheel speed sensor to the disc brake adapter. The remove bolt attaching speed sensor cable routing bracket to rear strut assembly. 6. Remove speed sensor head from the disc brake adapter. If the speed sensor head has seized in the adapter, DO NOT USE PLIERS ON SENSOR HEAD. INSTALL 1. Install wheel speed sensor head into disc brake adapter. 2. Install wheel speed sensor attaching bolt. Tighten the attaching bolt to a torque of 7 Nm (60 inch lbs.) 3. Install the brake flex hose and wheel speed sensor cable routing bracket on the rear strut bracket. 4. Install wheel speed sensor cable into the routing clips on the rear brake flex hose and chassis brake tube. 5. Plug speed sensor cable connector into vehicle wiring harness. Install clip attaching speed sensor cable connector to vehicle body. 6. Install the tire and wheel assembly on vehicle. 7. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 18 Nm (165 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 406 Engine Coolant Temperature Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 407 Engine Coolant Temperature Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 408 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig.13 Engine Coolant Temperature Sensor-DOHC PURPOSE The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. - The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. OPERATION As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The coolant sensor threads into the intake manifold next to the thermostat housing (Fig. 13). New sensors have sealant applied to the threads. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. The sensor also operates the engine cool and temperature gauge in the instrument cluster on circuit G20. See: Engine, Cooling and Exhaust/Cooling System/Lamps and Indicators Cooling System/Temperature Gauge/Description and Operation From circuit K2 the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes causing a change in current draw. The K2 circuit connects to cavity 26 of the PCM connector. The PCM provides ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig. 80 Engine Coolant Temperature Sensor Location-DOHC 1. With the key off, disconnect wire harness connector from coolant temperature sensor (Fig. 80). Fig. 27 Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 27). The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 28 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing > Page 411 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Helpful Information The engine coolant temperature sensor is case grounded. The case ground provides the ground for the coolant temperature gauge circuit G20. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 412 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig.39 Engine Coolant Temperature Sensor-DOHC NOTE: The engine coolant temperature sensor threads into the rear of the cylinder head. New sensors have sealant applied to the threads. REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. - Tighten to 18 Nm (165 in lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation Cruise Control Switch: Description and Operation SYSTEM OPERATION There are two separate switch pods that operate the speed control system. The steering-wheel/mounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF RESUME/ACCELERATE, SET/COAST and CANCEL modes. Refer to the owner's manual for more information on speed control switch functions and setting procedures. When speed control is selected by depressing the ON switch, the PCM allows a set speed to be stored in RAM for speed control. To store a set speed, depress the COAST/SET switch while the vehicle is moving at a speed between 30 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: An indication of Park or Neutral - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - An rpm increase without a VSS signal increase (indicates that the clutch has been disengaged) - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the RES/ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM is programmed for an acceleration feature. With the RES/ ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the RAM when the RES/ACCEL switch is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the RES/ACCEL switch. The PCM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the SET/COAST switch until the desired speed is reached. Then release the switch. The ON and OFF switches operates two components: the PCM's ON/OFF input, and the battery voltage to the brake switch, which powers the speed control servo. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Page 417 Cruise Control Switch: Testing and Inspection The speed control switches mounted on the steering wheel contain five switches and four resistors. The PCM sends 5 Volts through pin 41 to the speed control switches. The input on pin 41 is responsible for identifying the following: Resume/Accelerate, Set/ Coast, On, Off and Cancel. This is accomplished by multiplexing. Multiplexing allows the PCM to identify more than one signal from a single wire. To accomplish this, the speed control switch uses resistors that cause different voltage signals at pin 41. The 5-Volt signal at pin 41 has no path to ground when no buttons are depressed, allowing the PCM to recognize the open circuit. When the ON, OFF switch contacts are closed, the 5 Volt signal is pulled through a 15400 ohm resistor to ground providing a voltage of 4.14 to 4.73 Volts at pin 41. Once the PCM recognizes the ON signal, the PCM provides a battery voltage signal to the speed control servo through pin 5 of the 80-way connector. When the SET/COAST switch is depressed, a momentary contact closes a path to ground through a 2,940 ohm resistor. This causes a voltage of approximately 1.99 to 3.20 Volts at pin 41, indicating that the SET/COAST switch has been depressed. When the RES/ACCEL switch is depressed, a momentary contact closes to ground through a 6,650 ohm resistor. The 5-volt signal then passes through a higher resistance than that of the SET/COAST switch, causing the voltage to be approximately 3.30 to 4.14 Volts. When the OFF switch is depressed, the contacts close directly to ground, causing the 5-Volt signal to drop to 0 Volts. When the CANCEL is pressed the contact closes to ground through a 920 ohm resister, causing voltage at pin 41 of 0.61 to 1.94 Volts. Ohmmeter Check Of Switch Speed Control Switch 1. Remove the ON, OFF speed control switch assembly and disconnect the two-way connector. 2. Using an ohmmeter, touch one lead to one Pin and the second lead to the other Pin. The meter should read no continuity. Press the OFF button, the ohmmeter should read 0 to 0.5 ohms. Press the ON button, the ohmmeter should read 15,245 to 15,555 ohms. If the resistance does not fall within these values replace switch. 3. Remove the RESUME/SET/CANCEL speed control switch assembly and disconnect the two-way connector. 4. Using an ohmmeter, touch one lead to one Pin and the second lead to the other Pin. The meter should read no continuity Press the SET button, the ohmmeter should read 2,910 to 2,970 ohms. Press the RESUME button, the ohmmeter should read 6,580 to 6,720 ohms. Press the CANCEL button, the ohmmeter should read 900 to 920 ohms. If the resistance values do not fall within these specification replace the switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection Blower Motor Switch: Testing and Inspection Heater A/C Blower Switch Test 1. Remove Heater A/C control module. Blower Switch Test 2. Use a ohmmeter, and check continuity between the terminals of the switch as shown in the Blower Switch Test. 3. If the switch fails any part of the continuity test, other then Pin 1 to Pin 7, replace Heater A/C Control. If no continuity between Pin 1 to Pin 7 check the lamps, replace if necessary. Heater Blower Switch Test 1. Remove heater control. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Page 422 Heater Blower Switch Test 2. Use a ohmmeter, and check continuity between the terminals of the switch as shown in the Heater Blower Test. 3. If switch fails any part of the continuity test, other then Pin 1 to Pin 7, replace heater control. If no continuity between Pin 1 to Pin 7 check the lamps, replace if necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Page 423 Blower Motor Switch: Service and Repair The switch is not serviced, replace heater A/C control. Refer to Heating and Air Conditioning/Control Assembly/service and Repair. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Locations Evaporator Temperature Sensor/Clutch Cycling Switch: Locations Evaporator Probe Location The evaporator probe is located in the Evaporator Case unit housing and placed in the evaporator fins. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions Evaporator Temperature Sensor/Clutch Cycling Switch: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 429 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 430 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 431 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 432 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 433 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 434 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 435 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 436 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 437 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 438 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 439 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 440 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 441 Evaporator Temperature Sensor/Clutch Cycling Switch: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 442 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 443 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 444 Evaporator Temperature Sensor/Clutch Cycling Switch: Description and Operation EVAPORATOR PROBE The evaporator probe can be replaced without having to remove the unit housing from the vehicle. The evaporator probe is located in the unit housing and placed in the evaporator fins. the probe prevents evaporator freeze-up. This is done by cycling the compressor clutch OFF when evaporator temperature rises above freeze point. It cycles ON when the evaporator temperature rises above freeze point. The evaporator probe uses a thermistor probe in a capillary tube. The tube is inserted between the evaporator fins in the heater-A/C unit housing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 445 Evaporator Temperature Sensor/Clutch Cycling Switch: Testing and Inspection CAUTION: The work area and vehicle must be between 16° C (60° F) and 32° C (90° F) when testing the switch. 1. Disconnect the three wire connector from the evaporator probe lead located behind the glove box. 2. Start engine and set A/C to low blower motor speed, panel, full cool, and RECIRC. Evaporator Probe Harness Connector 3. Using a voltmeter, check for battery voltage between Pin 1 and 2. If no voltage is detected, there is no power to the switch. Check wiring and fuses. 4. Using a voltmeter, check for battery voltage between Pin 1 and Pin 3. If no voltage is detected, there is no voltage from the Powertrain Control Module. If voltage is OK, connect a jumper wire between Pin 1 and Pin 3. The compressor clutch should engage. If the clutch engages, remove the jumper wire immediately and go to Step 5. If the compressor clutch does not engage, check the operation of the clutch and repair as necessary. 5. If compressor clutch engages, connect the evaporator probe 3-way connector. The compressor clutch should engage or cycle depending on evaporator temperature. If OK, go to Step 6. If not OK, replace the clutch cycling switch. 6. The engine running and the A/C set to: - Blower motor on low speed - Panel position - Full cool - RECIRC. - Close all doors and windows. Place a thermometer in the center discharge vent. 7. If the clutch does not begin to cycle off between 2° C to 7° C (35° F to 45° F), verify that the evaporator probe is fully installed and not loose in evaporator. If it is not properly installed, install probe and reset outlet temperature. If the evaporator probe is properly installed, replace the clutch cycling switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 446 Evaporator Temperature Sensor/Clutch Cycling Switch: Service and Repair REMOVAL NOTE: The evaporator probe can be replaced without having to remove the unit housing from the vehicle. 1. Disconnect probe wiring connector from behind the glove box. Evaporator Probe Location 2. Remove rubber grommet from evaporator blower module. 3. Note in which of the three pilot holes the evaporator probe is located. 4. Pull probe out of evaporator fins. INSTALLATION 1. There are three pilot holes available for the probe. The top hole is for service. If top hole was not used by previous probe, install probe in top hole. 2. If previous probe was removed from top hole, use a small plastic stick and make a new hole. Make the hole 1/4 inch above or below the original hole in the evaporator core. 3. Insert new probe into hole between evaporator fins. 4. Reinstall rubber grommet into evaporator probe access hole. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations High Pressure Cut Out Switch The high pressure cut out switch is located in the compressor manifold. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 451 High Pressure Sensor / Switch: Description and Operation HIGH PRESSURE CUT-OFF SWITCH The High Pressure Cut-Off Switch turns off the compressor if the system pressure exceeds 3240 kPa (470 psi). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 452 High Pressure Sensor / Switch: Service and Repair WARNING: The refrigerant must be removed from the system before removing the high pressure cut out switch. REMOVAL High Pressure Relief Valve 1. Disconnect wiring connector at the switch. 2. Remove internal snap ring. 3. Pull switch out of manifold. INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Low Pressure Sensor / Switch: Locations Low Pressure Cut Off Switch The low pressure cut off switch is located on the expansion valve. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 456 Low Pressure Sensor / Switch: Description and Operation DESCRIPTION The Low Pressure Cut Off Switch monitors the refrigerant gas pressure on the suction side of the system. OPERATION It turns off voltage to the compressor clutch coil when refrigerant gas pressure drops to levels that could damage the compressor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 457 Low Pressure Sensor / Switch: Testing and Inspection CAUTION: The work area must not be below 21°C (70°F) to test the compressor clutch circuit. 1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Raise hood and disconnect low pressure cut off switch connector boot. 3. Using a suitable jumper wire, jump across the terminals inside wire connector boot. 4. If the compressor clutch does not engage, the cycling clutch switch, wiring, relay, or fuse can be defective. 5. If clutch engages, connect manifold gauge set. Read low pressure gauge. At pressure above 97 kPa (14 psi) and above, low pressure out off switch will complete the clutch circuit. If the low pressure gauge reads below 140 kPa (20 psi), the system is low on refrigerant charge or empty due to a leak. 6. Install connector boot on switch and repeat Step 3. If the clutch does not engage, replace the low pressure cut off switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 458 Low Pressure Sensor / Switch: Service and Repair The low pressure cut out switch is a sealed factory calibrated unit. It must be replaced if defective. WARNING: The refrigeration system must be completely recovered before proceeding with this operation. REMOVAL 1. Disconnect the boot like wire connector at the cut off switch. Low Pressure Cut Off Switch 2. Using a sender unit removal socket, remove the switch from the expansion valve. INSTALLATION NOTE: Verity the 0-ring condition on the replacement switch. For installation, reverse the above procedures. Evacuate and charge the system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: Customer Interest Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 468 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: All Technical Service Bulletins Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 474 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > General Description Fuel Gauge Sender: Description and Operation General Description Fig. 10 Level Sensor Diagnosis OPERATION The fuel gauge sending unit is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and two variable resistors (tracks). These two tracks are used to send two different electrical signals. One is used for fuel gauge operation and the other is for OBD II emission requirements. Track 1 fuel gauge operation: As the fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge on the instrument panel to read full. As the fuel level decreases, the float and arm move down. This increases the sending unit resistance, causing the fuel gauge on the instrument panel to read empty Track 2-OBD II emission requirements: A variable voltage signal is sent to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes if the fuel level in the tank is less than 15 percent of its rated capacity. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > General Description > Page 479 Fuel Gauge Sender: Description and Operation Related Trouble Codes and Set Conditions Fuel Level Sending Unit Volts Too High Name of Code: Fuel Level Sending Unit Volts Too High When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes above a calculated value. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel systems monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Open sensor signal circuit - Fuel level sending unit failure - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Fuel Level Sending Unit Volts Too Low Name of Code: Fuel Level Sending Unit Volts Too Low When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes below 0.10 volts. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel system monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Sensor signal circuit shorted to ground - Fuel level sending unit failure - Loss of fuel ignition switch output voltage - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Sending Unit Operation Check Fuel Gauge Sender: Testing and Inspection Sending Unit Operation Check When a problem occurs with a cluster gauge check for a defective sending unit or wiring. Do this before disassembling the cluster. 1. Sending units and wiring can be checked by grounding the connector leads at the sending unit in the vehicle. 2. With the ignition in the ON position, a grounded input will cause the fuel or temperature gauge to read at or above maximum. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 482 Fuel Gauge Sender: Testing and Inspection Sending Unit Voltage Check Fig. 1 Fuel Guage Test Terminal 1. Remove the fuel gauge electrical harness. 2. Connect 12 volt test light to the fuel gauge and ground terminal. 3. Turn ignition to On position and proceed as follows: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 483 a. If test light illuminates and pointer of gauge does not swing, replace fuel gauge. b. If test light illuminates and pointer of gauge swings, replace fuel gauge unit. c. If test light does not light and pointer of gauge does not swing, check the electrical harness for kinks chaffing and broken wires. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 484 Fuel Gauge Sender: Testing and Inspection Sending Unit Resistance Check Fig. 10 Level Sensor Diagnosis This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. To test the level sensor, connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector. Move the float lever to the positions shown in the resistance chart. Record the resistance at each point. Replace the level sensor if the resistance is not within specifications. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 485 Fuel Gauge Sender: Service and Repair Fig. 21 Fuel Pump/Level Sensor Electrical Connector NOTE: Remove fuel pump module prior to beginning this procedure. REMOVAL 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector. Fig. 22 Wire Terminal Locking Wedge 2. Pull off blue locking wedge. Fig. 23 Wire Terminal Locking Finger 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 486 Fig. 24 Removing Wires From Connector 4. Push level sensor signal and ground terminals out of the connector. Fig. 25 Loosening Level Sensor 5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Fig. 26 Level Sensor Removal/Installation 6. Push level sensor down slightly. - Ensure tab at bottom of sensor locks in place. 7. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 8. Install locking wedge on connector. 9. Push connector up into bottom of fuel pump module electrical connector. 10. Install fuel pump module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications Backup Lamp Switch: Specifications Mounting .............................................................................................................................................. .................................................... 24 Nm (18 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications > Page 491 Backup Lamp Switch: Testing and Inspection The park/neutral starting switch is the center terminal of the three terminal switch. It provides ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Automatic Transmission Backup Lamp Switch: Service and Repair Automatic Transmission REMOVAL Unscrew switch from transaxle case allowing fluid to drain into a container. Move selector lever to PARK, then to NEUTRAL position, and inspect to see the switch operating lever fingers are centered in switch opening. INSTALLATION 1. Screw the switch with a new seal into transaxle case and tighten to 33 Nm (24 ft. lbs.). Retest switch with the test lamp. 2. Add fluid to transaxle to bring up to proper level. 3. The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 4. To test switch, remove wiring connector from switch and test for continuity between the two outside pins. 5. Continuity should exist only with transaxle in REVERSE position. 6. No continuity should exist from either pin to the case. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Automatic Transmission > Page 494 Backup Lamp Switch: Service and Repair Manual Transmission NOTE: The back-up lamp switch is located on the top left front side of the transaxle case. REMOVAL 1. Lift vehicle on hoist. 2. From bottom side of vehicle, remove wiring connector from switch. 3. Unscrew switch from transaxle. INSTALLATION 1. To install, reverse removal procedure. Teflon tape or equivalent must be used on switch threads. CAUTION: Do not overtighten switch. 2. Confirm back-up lamps are functioning properly following installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service Precautions Brake Light Switch: Service Precautions CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Switch Operation Brake Light Switch: Description and Operation Switch Operation The stop lamp switch controls operation of the vehicles stop lamps. Also, if the vehicle is equipped with speed control, the stop lamp switch will deactivate speed control when the brake pedal is depressed. The stop lamp switch controls operation of the right and left tail, stop and turn signal lamp and Center High Mounted Stop Lamp CHMSL, by supplying battery current to these lamps. The stop lamp switch controls the lamp operation by opening and closing the electrical circuit to the stop lamps. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Switch Operation > Page 500 Brake Light Switch: Description and Operation System Operation SYSTEM OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The switch is mounted in the same location as the conventional stop lamp switch, on the brake pedal mounting bracket under the instrument panel. The PCM monitors the state of the dual function stop lamp switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 501 Brake Light Switch: Testing and Inspection Fig. 21 Stop Lamp Switch 1. Remove the stop lamp switch, refer to Lighting and Horns/Brake Light Switch/Stop Switch Removal/Installation. Disconnect connector from stop lamp switch. Using an ohmmeter, switch continuity may be checked as follows: 2. With switch plunger released, there should be continuity between Pin 5 and Pin 6. 3. With switch plunger depressed, there should be continuity: - Between Pin 1 and Pin 2. - Between Pin 3 and Pin 4. 4. If the above results are not obtained, the stop lamp switch is defective or out of adjustment. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 502 Brake Light Switch: Adjustments Stop Light Switch Location In Vehicle PROCEDURE 1. Remove stop lamp switch from its bracket by rotating it approximately 30° in a counter-clockwise direction. 2. Disconnect wiring harness connector from stop lamp switch. 3. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position. 4. Install the stop lamp switch into the bracket using the following procedure. Depress the brake pedal as far down as possible. Then while keeping the brake pedal depressed, install the stop lamp switch into the bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When switch is fully installed in the square hole of the bracket, rotate switch clockwise approximately 30° to lock the switch into the bracket. CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result. 5. Connect the wiring harness connector to the stop lamp switch. 6. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 503 Brake Light Switch: Service and Repair Stop Light Switch Location In Vehicle REMOVE 1. Depress and hold the brake pedal while rotating stop lamp switch in a counter-clockwise direction approximately 30°. 2. Pull the switch rearward and remove from its mounting bracket. 3. Disconnect wiring harness connector from stop lamp switch. INSTALL NOTE: Prior to installing stop lamp switch into bracket, the plunger must be moved to its fully extended position using procedure in step Step 1. 1. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position. 2. Connect the wiring harness connector to the stop lamp switch. 3. Mount the stop lamp switch into the bracket using the following procedure. Depress the brake pedal as far down as possible. Then install switch in bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When switch is fully installed in bracket, rotate switch clockwise approximately 30° to lock switch into bracket. CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If too much force is used, damage to the stop lamp switch or striker can result. 4. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection Combination Switch: Testing and Inspection The multi-function switch contains electrical circuitry for turn signal, hazard warning, headlamp beam select, headlamp optical horn. This integrated switch assembly is mounted to the left hand side of the steering column. Should any function of the switch fail, the entire switch assembly must be replaced. Turn Signal And Hazard Switch Continuity Beam Select Switch Continuity To test the switch, first disconnect the negative battery cable, then remove the upper and lower column shrouds to gain access to the switch connector. Remove switch connector. Using an ohmmeter, test for continuity (no resistance) between the terminals of the switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 507 Combination Switch: Service and Repair REMOVAL 1. Disconnect battery negative cable. 2. Remove both upper and lower steering column shrouds. Multi-Function Switch 3. Remove multi-function switch mounting screws. INSTALLATION For installation, reverse the above procedures. - Tighten multi-function switch to column retaining screws to 2 N.m (17 in. lbs.) torque. - Tighten steering column cover retaining screws to 2 N.m (17 in. lbs.) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: Customer Interest Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 516 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: All Technical Service Bulletins Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 522 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Testing and Inspection Fog/Driving Lamp Switch: Testing and Inspection 1. Remove the fog lamp switch. 2. Using two jumper wires, connect Pin 2 and Pin 4 of the switch to battery voltage. Fog Lamp Switch Test Fog Lamp Switch Circuit 3. Using a test lamp, connect the test lamp to Pin 3 as shown in for fog lamp switch circuit. 4. Push the fog lamp switch button. The test lamp and the LED indicator on the front of the switch should illuminate. 5. If either the LED or the test lamp fails to illuminate, replace the switch. Front Export 1. Remove the fog lamp switch and disconnect the connector at the center stack. Front Fog Lamp Switch Circuit Diagram 2. Using two jumper wires connect Pin L7 to battery voltage, and connect Pin Z03 to ground. 3. Push the fog lamp switch button. The LED indicator on the front of the switch should illuminate. Check Pin L35 with a test lamp for battery voltage. 4. If either the LED or the test lamp fails to illuminate, replace the switch. Rear Export 1. Remove the fog lamp switch. 2. Using two jumper wires connect Pin 2 and Pin 4 of the switch to battery voltage. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Testing and Inspection > Page 526 Rear Fog Lamp Switch Test 3. Using a test lamp, connect the test lamp to Pin 3 as shown in. 4. Push the fog lamp switch button. The test lamp should illuminate, and the LED indicator on the front of the switch. 5. If either the LED, or the test lamp fails to illuminate, replace the switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Front Fog Lamp Switch Export Fog/Driving Lamp Switch: Service and Repair Front Fog Lamp Switch Export REMOVAL 1. Disconnect the wire connector in the center stack, EUX left side and RHD right side. 2. Remove the floor console and disconnect the two clips attaching the wire harness from the underside of the floor console. 3. Remove the switch bezel from the floor console. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Front Fog Lamp Switch Export > Page 529 Fog/Driving Lamp Switch: Service and Repair Rear Window Defogger and/or Fog Lamp Switch REMOVAL 1. Remove the top cover and cluster bezel assembly. Rear Window Defogger And Fog Lamp Switch 2. Reach in and disengage the left bezel latch and remove assembly. 3. Pull the bezel and switch(s) rearward from the opening and disconnect the wire connector(s). 4. Remove the switch from the bezel. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Front Fog Lamp Switch Export > Page 530 Fog/Driving Lamp Switch: Service and Repair Rear Window Defogger and/or Fog Lamp Switch Export REMOVAL 1. Remove the top cover and cluster bezel assembly. Rear Window Defogger And Rear Fog Lamp Switch 2. Reach in and disengage the left bezel latch and remove the assembly. 3. Pull the bezel and switch(s) rearward from the opening and disconnect the wire connector(s). 4. Remove the switch from the bezel. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair REMOVAL 1. Disconnect battery negative cable and isolate it or remove fuse 12 prior to removing the switch, or wires may short to ground. 2. Open the glove box and push the glove box sides inward allowing the door bumpers to clear and the box to tip forward. 3. Reach inside the opening and squeeze the lamp/switch retainers until they are disengage. 4. Pull the switch/lamp rearward and remove it. Replace the lamp. To replace the switch disconnect wire and replace the switch. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection Hazard Warning Switch: Testing and Inspection The multi-function switch contains electrical circuitry for turn signal, hazard warning, headlamp beam select, headlamp optical horn. This integrated switch assembly is mounted to the left hand side of the steering column. Should any function of the switch fail, the entire switch assembly must be replaced. Turn Signal And Hazard Switch Continuity Beam Select Switch Continuity To test the switch, first disconnect the negative battery cable, then remove the upper and lower column shrouds to gain access to the switch connector. Remove switch connector. Using an ohmmeter, test for continuity (no resistance) between the terminals of the switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 537 Hazard Warning Switch: Service and Repair REMOVAL 1. Disconnect battery negative cable. 2. Remove both upper and lower steering column shrouds. Multi-Function Switch 3. Remove multi-function switch mounting screws. INSTALLATION For installation, reverse the above procedures. - Tighten multi-function switch to column retaining screws to 2 N.m (17 in. lbs.) torque. - Tighten steering column cover retaining screws to 2 N.m (17 in. lbs.) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation Headlamp Switch: Description and Operation CIRCUIT OPERATION In OFF or Parking Lamp Position Circuit A3 originates in the Power Distribution Center (PDC) and supplies battery voltage for the headlamp switch. A 40 Amp fuse protects the A3 circuit. The headlamp switch has an internal 24 Amp circuit breaker that connects circuit A3 to either the L2 or L20 circuits, depending on switch position. In the OFF and PARK positions the headlamp switch feeds the L20 circuit that connects to the multi-function switch. Circuit L20 powers the high beam circuit when the operator flashes the headlamps with the turn signal stalk of the multi-function switch. when the operator flashes the headlamps with the stalk, the multi-function switch connects the L20 circuit to the L3 circuit. The L3 circuit feeds the high beam of the headlamps. In ON Position When the headlamp switch is in the ON position, it connects the A3 circuit from the PDC to circuit L2. Circuit L2 connects to the multi-function switch and feeds the L4 circuit (for low beam operation). The L4 circuit connects to a bus bar in the fuse block. Circuits L43 and L44 connect to the bus bar in fuse block and power the low beam headlamps. Circuit L43 supplies voltage to the left headlamp. Circuit L44 supplies voltage to the right headlamp. Both the L43 and L44 circuits have separate 10 Amp fuses located in fuse block. Fuse 17 protects circuit L43, and fuse 18 protects circuit L44. When the operator selects high beam operation with the turn signal stalk of the multi-function switch, circuit L2 connects to the L3 circuit, Circuit L3 powers high beam operation. On vehicles equipped with Remote Keyless Entry (RKE) the L4 circuit is spliced to the RKE module. The RKE module uses this circuit to flash the headlamps when the operator has activated the PANIC mode with the key fob. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Headlamp Leveling Switch Headlamp Switch: Testing and Inspection Headlamp Leveling Switch 1. Remove the headlamp leveling switch from the instrument panel and disconnect the wire harness connector from the switch. 2. If the L.E.D. is not illuminated, using a voltmeter, connect B+ lead to Pin 4 of the Wire harness connector. Connect the negative lead to Pin 3. Turn ON the headlamp switch to the low beam position and ensure the instrument panel dimmer switch is on day light driving position. If voltage is present, replace switch. If no voltage, connect the ground lead to a good ground, if voltage, repair Pin 3 ground circuit as necessary, and if no voltage. 3. Using a voltmeter, connect B+ lead to Pin 2 of the Wire harness connector. Connect the negative lead to Pin 3. Turn ON the headlamp switch to the low beam position. If battery voltage, go to Step 5. If not OK, go to Step 4. 4. Connect the ground lead to a good ground, if no voltage, refer to Wiring Diagrams and test circuit back to headlamp switch. If battery voltage, repair Pin 3 ground circuit as necessary 5. Turn headlamps OFF. Connect the wire harness connector to the headlamp leveling switch. Turn ON the headlamp switch to the low. beam position. Check voltage at Pin 5, while rotating the headlamp leveling switch knob through the four positions. The voltage reading should change as the switch is rotated to each position. If the voltage does not vary replace switch. If OK, test the headlamp leveling motors and/or circuit to the motors. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Headlamp Leveling Switch > Page 543 Headlamp Switch: Testing and Inspection Headlamp Switch Test Headlamp Switch Test 1. Remove the headlamp switch. 2. Use a ohmmeter, and check continuity between the terminals of the switch as shown in the Headlamp Switch Test. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Leveling Switch Export Headlamp Switch: Service and Repair Headlamp Leveling Switch Export REMOVAL 1. Remove the top cover and cluster bezel assembly Headlamp Leveling Switch 2. Disengage the headlamp leveling switch bezel from instrument panel . 3. Pull the switch and bezel rearward from the opening and disconnect the wire connector. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Leveling Switch Export > Page 546 Headlamp Switch: Service and Repair Headlight Switch REMOVAL 1. Remove the steering column cover and liner. Headlamp Switch 2. Remove the three screws securing headlamp switch mounting plate to the instrument panel. 3. Pull the headlamp switch and mounting plate rearward from the instrument panel opening. 4. Disconnect both the nine way and the ground wiring connectors from the switch. 5. Remove the switch knob by depressing the release button on the bottom on the switch and pulling out knob from switch. 6. Snap headlamp switch bezel out of mounting plate to gain access to the mounting plate retaining nut. 7. Remove the headlamp switch, mounting plate retaining nut and separate switch from mounting plate. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation Horn Switch: Description and Operation Horn Switch The horn switch is mounted between the outer and inner cover of the Driver Airbag Module. When the Driver Airbag is pressed the horn switch makes contact to ground. The ground signal is carried to the horn relay and the horn sounds. 1. The horn switch grounds to the airbag housing. 2. If horn does not sound check for corrosion: - Horn wire - Horn switch ground connected to airbag metal housing - Airbag to steering wheel - Ensure horn wire is properly connected and insulator is in place on wire. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Page 550 Horn Switch: Testing and Inspection 1. Remove horn relay from the Power Distribution Center. Power Distribution Center 2. Using ohmmeter, connect one lead to ground and the other lead to cavity 65 of the power distribution center. 3. Depress horn switch, should have continuity. If no continuity go to Step 4. 4. Test continuity at horn switch remove the Driver Airbag Module. Refer to Air Bags and Seat Belts/Air Bag Control Module/Replacement/Driver Airbag Module. Test Horn Switch Driver Airbag Module 5. Using ohmmeter, connect one lead to the airbag module ground and the other lead to B+ wire. 6. Depress horn switch, and the meter should show continuity. If no continuity, replace the Driver Airbag Module. If OK, repair as necessary. . Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Page 551 Horn Switch: Service and Repair The Horn Switch is part of the Driver Airbag Module. Refer to Air Bags and Seat Belts/Air Bag Control Module/Replacement. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Service Precautions Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Service Precautions > Page 557 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature. This temperature data, along with data from monitored line voltage, is used by the (PCM) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Battery Temperature Sensor The sensor is located forward of the vehicle battery, and is attached to the battery tray. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to Powertrain Management/Computer and Controls/Testing and Inspection. 1. The sensor is located under the battery and is attached to the battery tray. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25 °C (75-80 °F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) Ohms should be observed. 5. If reading is above or below the specification, replace the sensor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 560 Battery Temperature Sensor: Service and Repair REMOVE 1. Make sure ignition switch is in OFF position and all accessories are OFF. Disconnect Battery Negative Cable 2. Remove battery negative cable first then the positive cable. Battery Thermoguard 3. Remove battery thermoguard. WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN. Air Inlet Tube Pull Strap Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 561 4. Remove temperature sensor mounting nut from battery tray. Battery Temperature Sensor Connector 5. Disconnect sensor wire connector. INSTALL - For installation reverse above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis > Page 566 Camshaft Position Sensor: Technical Service Bulletins Cam/Crank Sensor - No Start Diagnostics NO: 18-24-97 GROUP: Vehicle Performance DATE: Aug. 8, 1997 SUBJECT: No Start Diagnostics Cam/Crank Sensor $01 and $28 MODELS: 1997 (FJ) Avenger/Sebring/Talon 1997 (GS) Chrysler Voyager (International Market) 1997 (JA) Breeze/Cirrus/Stratus 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1997 (NS) Town & Country/Caravan/Voyager 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L DOHC/SOHC (NATURALLY ASPIRATED), 2.4L, 3.3L, 3.5L, OR 3.8L ENGINE. DISCUSSION: If a vehicle exhibits a no-start due to failure of the cam or crank sensor, the opposite sensor may be reported as the DTC (i.e. bad cam sensor sets crank sensor DTC and vice versa). The faulty sensor may generate a signal strong enough (at key "ON") to be interpreted by the controller as a legitimate signal. Since the engine is not running, the opposite sensor will not be generating any pulses. The controller, expecting corresponding pulses from both sensors, matures a fault for the sensor that is not generating any pulses. In this case, the good sensor is reported as faulty. To verify which sensor is at fault, use the DRB III and select DRB III Standalone, 1994 - 1998 Diagnostics, select Engine system, select Monitor Display, and No Start monitor. Under the No Start monitor the cam and crank sensors should display a no response or LOST on the display. If a sensor is reporting a signal at key ON", it should be replaced. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 569 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 570 Camshaft Position Sensor: Locations Camshaft Position Sensor Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 571 Camshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 572 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity OPERATION The camshaft position sensor attaches to the rear of the cylinder head. A target magnet attaches to the rear of the camshaft and indexes to the Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 573 correct position. The target magnet has four different poles arranged in an asymmetrical pattern (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the camshaft position sensor The K7 circuit connects to cavity 44 of the PCM connector. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 33 of the PCM connector. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing Camshaft Position Sensor: Testing and Inspection Component Testing The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting an oscilloscope and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing > Page 576 Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing > Page 577 Camshaft Position Sensor: Testing and Inspection Failure to Start Test Fig.20 Ignition Coil Engine Harness Connector This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Sensor Replacement Camshaft Position Sensor Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head. REMOVAL 1. Remove filtered air tube from the throttle body and air cleaner housing. 2. Disconnect electrical connector from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.35 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft (Fig. 35). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 580 Fig.36 Target Magnet Installation NOTE: The target magnet has locating dowels that fit into machined locating holes in the end of the camshaft (Fig. 36). INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install filtered air tube. Tighten clamps to 3 Nm ±1 (25 in lb ±5) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 581 Camshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 18 Nm (165 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 585 Engine Coolant Temperature Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 586 Engine Coolant Temperature Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 587 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig.13 Engine Coolant Temperature Sensor-DOHC PURPOSE The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. - The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. OPERATION As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The coolant sensor threads into the intake manifold next to the thermostat housing (Fig. 13). New sensors have sealant applied to the threads. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. The sensor also operates the engine cool and temperature gauge in the instrument cluster on circuit G20. See: Engine, Cooling and Exhaust/Cooling System/Lamps and Indicators Cooling System/Temperature Gauge/Description and Operation From circuit K2 the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes causing a change in current draw. The K2 circuit connects to cavity 26 of the PCM connector. The PCM provides ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig. 80 Engine Coolant Temperature Sensor Location-DOHC 1. With the key off, disconnect wire harness connector from coolant temperature sensor (Fig. 80). Fig. 27 Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 27). The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 28 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing > Page 590 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Helpful Information The engine coolant temperature sensor is case grounded. The case ground provides the ground for the coolant temperature gauge circuit G20. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 591 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig.39 Engine Coolant Temperature Sensor-DOHC NOTE: The engine coolant temperature sensor threads into the rear of the cylinder head. New sensors have sealant applied to the threads. REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. - Tighten to 18 Nm (165 in lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Cam/Crank Sensor - No Start Diagnostics Crankshaft Position Sensor: Technical Service Bulletins Cam/Crank Sensor - No Start Diagnostics NO: 18-24-97 GROUP: Vehicle Performance DATE: Aug. 8, 1997 SUBJECT: No Start Diagnostics Cam/Crank Sensor $01 and $28 MODELS: 1997 (FJ) Avenger/Sebring/Talon 1997 (GS) Chrysler Voyager (International Market) 1997 (JA) Breeze/Cirrus/Stratus 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1997 (NS) Town & Country/Caravan/Voyager 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L DOHC/SOHC (NATURALLY ASPIRATED), 2.4L, 3.3L, 3.5L, OR 3.8L ENGINE. DISCUSSION: If a vehicle exhibits a no-start due to failure of the cam or crank sensor, the opposite sensor may be reported as the DTC (i.e. bad cam sensor sets crank sensor DTC and vice versa). The faulty sensor may generate a signal strong enough (at key "ON") to be interpreted by the controller as a legitimate signal. Since the engine is not running, the opposite sensor will not be generating any pulses. The controller, expecting corresponding pulses from both sensors, matures a fault for the sensor that is not generating any pulses. In this case, the good sensor is reported as faulty. To verify which sensor is at fault, use the DRB III and select DRB III Standalone, 1994 - 1998 Diagnostics, select Engine system, select Monitor Display, and No Start monitor. Under the No Start monitor the cam and crank sensors should display a no response or LOST on the display. If a sensor is reporting a signal at key ON", it should be replaced. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 598 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position Sensor Bolts ........................................................................................................ .......................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 599 Fig 7 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 600 Crankshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 601 Crankshaft Position Sensor: Description and Operation Fig 7 Crankshaft Position Sensor Fig. 14 Timing Reference Notches Fig.6 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60° signature notch (Fig. 14). The notches generate pulses from high to low in the crankshaft position sensor output voltage. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 602 - When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69° before top dead center (BTDC). - The second notch represents 49° BTDC. - The third notch represents 29°. - The last notch in each set represents 9° before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM connector. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test Fig.20 Ignition Coil Engine Harness Connector This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 605 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig 7 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Crankshaft Position Sensor Bolts torque ....................................................................................................................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 608 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > General Description Fuel Level Sensor: Description and Operation General Description Fig. 10 Level Sensor Diagnosis OPERATION The fuel gauge sending unit is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and two variable resistors (tracks). These two tracks are used to send two different electrical signals. One is used for fuel gauge operation and the other is for OBD II emission requirements. Track 1 fuel gauge operation: As the fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge on the instrument panel to read full. As the fuel level decreases, the float and arm move down. This increases the sending unit resistance, causing the fuel gauge on the instrument panel to read empty Track 2-OBD II emission requirements: A variable voltage signal is sent to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes if the fuel level in the tank is less than 15 percent of its rated capacity. CIRCUIT OPERATION Circuit G4 provides an input to the Powertrain Control Module (PCM) indicating fuel tank level. This circuit connects to cavity 23 of the PCM connector. The G4 circuit is also used for the fuel gauge located in the instrument cluster. For operation of fuel gauge, See: Instrument Panel, Gauges and Warning Indicators/Fuel Gauge/Description and Operation Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > General Description > Page 613 Fuel Level Sensor: Description and Operation Related Trouble Codes and Set Conditions Fuel Level Sending Unit Volts Too High Name of Code: Fuel Level Sending Unit Volts Too High When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes above a calculated value. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel systems monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Open sensor signal circuit - Fuel level sending unit failure - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Fuel Level Sending Unit Volts Too Low Name of Code: Fuel Level Sending Unit Volts Too Low When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes below 0.10 volts. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel system monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Sensor signal circuit shorted to ground - Fuel level sending unit failure - Loss of fuel ignition switch output voltage - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Sending Unit Operation Check Fuel Level Sensor: Testing and Inspection Sending Unit Operation Check When a problem occurs with a cluster gauge check for a defective sending unit or wiring. Do this before disassembling the cluster. 1. Sending units and wiring can be checked by grounding the connector leads at the sending unit in the vehicle. 2. With the ignition in the ON position, a grounded input will cause the fuel or temperature gauge to read at or above maximum. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 616 Fuel Level Sensor: Testing and Inspection Sending Unit Voltage Check Fig. 1 Fuel Guage Test Terminal 1. Remove the fuel gauge electrical harness. 2. Connect 12 volt test light to the fuel gauge and ground terminal. 3. Turn ignition to On position and proceed as follows: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 617 a. If test light illuminates and pointer of gauge does not swing, replace fuel gauge. b. If test light illuminates and pointer of gauge swings, replace fuel gauge unit. c. If test light does not light and pointer of gauge does not swing, check the electrical harness for kinks chaffing and broken wires. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 618 Fuel Level Sensor: Testing and Inspection Sending Unit Resistance Check Fig. 10 Level Sensor Diagnosis This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. To test the level sensor, connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector. Move the float lever to the positions shown in the resistance chart. Record the resistance at each point. Replace the level sensor if the resistance is not within specifications. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Page 619 Fuel Level Sensor: Service and Repair Fig. 21 Fuel Pump/Level Sensor Electrical Connector NOTE: Remove fuel pump module prior to beginning this procedure. REMOVAL 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector. Fig. 22 Wire Terminal Locking Wedge 2. Pull off blue locking wedge. Fig. 23 Wire Terminal Locking Finger 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Page 620 Fig. 24 Removing Wires From Connector 4. Push level sensor signal and ground terminals out of the connector. Fig. 25 Loosening Level Sensor 5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Fig. 26 Level Sensor Removal/Installation 6. Push level sensor down slightly. - Ensure tab at bottom of sensor locks in place. 7. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 8. Install locking wedge on connector. 9. Push connector up into bottom of fuel pump module electrical connector. 10. Install fuel pump module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications MAP Sensor Torque Aluminum Manifold = 3 Nm (30 in lbs) Plastic Manifold = 2 Nm (20 in lbs) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 624 Map/Intake Air Temperature Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 625 Intake Air Temperature Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 626 Intake Air Temperature Sensor: Description and Operation Fig.15 MAP/IAT Sensor-DOHC PURPOSE The intake air temperature sensor measures the temperature of the air as it enters the engine. The sensor supplies one of the inputs the PCM uses to determine injector pulse-width. CONSTRUCTION The MAP/Intake Air Temperature (IAT) sensor, located on the intake manifold, combines the MAP and Intake Air Temperature (IAT) functions into one sensor. CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. Circuit K21 connects to cavity 37 of the PCM connector. From circuit K21 the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor As intake air temperature changes the resistance in the sensor changes causing a change in current draw. The PCM provides ground for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Intake Air Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 629 Intake Air Temperature Sensor: Service and Repair Map/Intake Air Temperature Sensor Fig. 98 MAP/IAT Sensor-DOHC NOTE: The MAP/IAT sensor attaches to the intake manifold plenum (Fig. 98). Fig. 97 Air Inlet Duct-DOHC REMOVAL 1. Remove air inlet duct wing nut and duct from intake manifold (Fig. 97). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 630 2. Disconnect the electrical connector from the MAP/IAT sensor. 3. Remove sensor mounting screws. 4. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seals. 2. Tighten mounting screws to 2 Nm (20 in lb) torque for a plastic manifold and 3 Nm (30 in lb) for a aluminum manifold. 3. Attach electrical connector to sensor 4. Install air inlet duct wing nut and duct from intake manifold, insure that the duct does not interfer with ignition cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 634 Knock Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 635 Knock Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 636 Knock Sensor: Description and Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 24 of the PCM connector. The PCM provides ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Helpful Information Knock Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 639 Knock Sensor: Testing and Inspection Component Testing The knock sensor can be tested with a digital voltmeter. Sensor output should be between 80 mV and 4 volts with the engine running between 576 and 2,208 rpm. If the output falls outside of this range a DTC will be set. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Page 640 Knock Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications Manifold Pressure/Vacuum Sensor: Electrical Specifications The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications > Page 645 Manifold Pressure/Vacuum Sensor: Mechanical Specifications MAP Sensor Torque Aluminum Manifold = 3 Nm (30 in lbs) Plastic Manifold = 2 Nm (20 in lbs) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 646 Map Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 647 IAT/Map Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 648 Manifold Pressure/Vacuum Sensor: Description and Operation Fig.15 MAP/IAT Sensor-DOHC OPERATION The PCM supplies 5 volts to the MAP sen son The MAP sensor function converts intake manifold pressure into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP sensor voltage decreases proportionately. Also, as vacuum decreases, MAP sensor voltage increases proportionately. During cranking, before the engine starts running, the PCM determines atmosphenc air pressure from the MAP sensor voltage. While the engine operates, the PCM determines intake manifold pressure from the MAP sensor voltage. Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and the air/fuel mixture. The MAP/Intake Air Temperature Sensor (MAP/IAT) sensor mounts to the intake manifold. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Manifold Absolute Pressure (MAP) sensor. Circuit K6 connects to cavity 61 of the PCM connector. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity 36 of the PCM connector. The PCM provides ground for the MAP sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing Manifold Pressure/Vacuum Sensor: Testing and Inspection Component Testing Fig. 82 MAP Sensor Connector CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 1 and 4 (Fig. 82). With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. If OK, go to next step. - If not OK, go to step 3. 2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness condition. Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 43. - If OK, go to next step. - If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 3 and 1 with the key ON. The voltage should be approximately 5 volts ± 0.5V). Five volts (± 0.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor. - If not OK, repair or replace the wire harness as required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing > Page 651 Manifold Pressure/Vacuum Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 652 Manifold Pressure/Vacuum Sensor: Service and Repair Map/Intake Air Temperature Sensor Fig. 98 MAP/IAT Sensor-DOHC NOTE: The MAP/IAT sensor attaches to the intake manifold plenum (Fig. 98). Fig. 97 Air Inlet Duct-DOHC REMOVAL 1. Remove air inlet duct wing nut and duct from intake manifold (Fig. 97). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 653 2. Disconnect the electrical connector from the MAP/IAT sensor. 3. Remove sensor mounting screws. 4. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seals. 2. Tighten mounting screws to 2 Nm (20 in lb) torque for a plastic manifold and 3 Nm (30 in lb) for a aluminum manifold. 3. Attach electrical connector to sensor 4. Install air inlet duct wing nut and duct from intake manifold, insure that the duct does not interfer with ignition cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Upstream and Downstream Heated Oxygen Sensors Torque = 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 659 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 660 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 661 Downstream Oxygen Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 662 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 663 Oxygen Sensor: Description and Operation CIRCUIT OPERATION Circuit A14 is a bus bar in the Power Distribution Center (PDC), and connects to battery voltage. The contact side of the Automatic Shut Down (ASD) relay connects circuit A14 and circuit A142. A 20 Amp fuse in the PDC protects circuits A14 and A142. Circuit A14 also supplies voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) controls the ground path circuit for the coil side of the ASD relay on circuit K51. Circuit K51 connects to cavity 67 of the PCM connector. Circuit A142 splices to supply voltage for the upstream and downstream heated oxygen sensors. The A142 circuit also splices to cavity 6 of the PCM. The input provided by circuit A142 at cavity 6 tells the PCM that the ASD relay energized. Circuit K41 delivers the signal from the upstream heated oxygen sensor to the PCM. Circuit K41 connects to cavity 30 of the PCM connector. Circuit K141 delivers the signal from the down-stream heated oxygen sensor to the PCM. Circuit K141 connects to cavity 51 of the PCM connector. The PCM provides a ground for the upstream and downstream heated oxygen sensor signals (circuit K41 and K141) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector Circuit Z1 provides ground for the heater circuits in each sensor. Circuit Z1 terminates at the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information Oxygen Sensor: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, ASD relay, generator, and the upstream and downstream heated oxygen sensors. The PCM controls the ground circuit for each of the components powered by circuit A142. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information > Page 666 Oxygen Sensor: Testing and Inspection Oxygen Sensor Heater Circuit Test NOTE: Use an ohmmeter to test the heating element of the oxygen sensors. 1. Disconnect the electrical connector from each oxygen sensor. - The white wires in the sensor connector are the power and ground circuits for the heater elements. 2. Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. - Replace the heated oxygen sensor if the resistance is not between 4 and 7 ohms. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor Oxygen Sensor: Service and Repair Downstream O2 Sensor Fig. 19 Downstream Heated Oxygen Sensor NOTE: The downstream heated oxygen sensor threads into the exhaust pipe behind the catalytic convertor (Fig. 19). REMOVAL 1. Raise vehicle. 2. Disconnect electrical connector from sensor. 3. Disconnect sensor electrical harness from clips along body. Fig. 20 Downstream Heated Oxygen Sensor Removal/Installation 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 20). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 669 Oxygen Sensor: Service and Repair Upstream O2 Sensor Fig. 18 Upstream Heated Oxygen Sensor Removal/Installation REMOVAL 1. Raise and support vehicle. 2. Unplug sensor connector. 3. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 18). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 670 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 675 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 676 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 677 Power Steering Pressure Switch: Description and Operation Fig. 15 Power Steering Pressure Switch PURPOSE On vehicles equipped with power steering, a power steering pressure switch is used to improve the vehicle's idle quality. The pressure switch improves vehicle idle quality, by controlling engine idle speed when required. The switch (Fig. 15) provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. OPERATION The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed is increased. This increase in engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. When power steering pump pressure exceeds 2,758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. The power steering pressure switch is mounted directly to the power steering gear on vehicles requiring its usage. CIRCUIT OPERATION The power steering pressure switch opens and closes circuit K10 between the Powertrain Control Module (PCM) and ground. Circuit K10 connects to cavity 45 of the PCM connector. Circuit Z12 provides ground for the power steering pressure switch. The grounding point for circuit Z12 is the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 678 Power Steering Pressure Switch: Service and Repair CAUTION: When removing and installing the power steering pressure switch, the use of a 7/8 inch deep well socket is required. The deep well socket will prevent damage to the plastic, electrical connector area, of the power steering pressure switch. REMOVE 1. Disconnect negative battery cable from the negative post of the battery. Be sure cable is isolated from negative post on battery. 2. Raise vehicle. 3. Locate power steering pressure switch on back side of power steering gear. 4. Remove vehicle wiring harness connector, from power steering pressure switch. 5. Remove power steering pressure switch, from power steering gear. CAUTION: When tightening the power steering pressure switch after installation in steering gear, do not exceed the torque specification shown in step 1 below. Over-tightening may result in stripping the threads out of the pressure switch port on the steering gear. INSTALL 1. Install power steering pressure switch into power steering gear by hand until fully seated. Then torque power steering pressure switch to 8 Nm (70 inch lbs.). 2. Install vehicle wiring harness connector onto power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with locking tab on power steering pressure switch. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar (R), Power Steering Fluid, or equivalent. 3. Fill power steering reservoir to correct fluid level. 4. Connect negative cable back on negative post of battery. 5. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 683 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 684 Throttle Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 685 Throttle Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 686 Throttle Position Sensor: Description and Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS mounts to the throttle body and connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- from 0.38 to 1.03 volts. - AT Wide open throttle -- 3.1 to 4.0 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). CIRCUIT OPERATION From the Powertrain Control Module (PCM) circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 689 Throttle Position Sensor: Testing and Inspection Component Testing To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool and follow the appropriate procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for correct pinout. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 690 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 691 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (20 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Throttle Position Sensor Mounting Screws 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 695 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 696 Transmission Position Switch/Sensor: Description and Operation Fig. 20 Park/Neutral Switch OPERATION On vehicles with 3-speed automatic transmission the park/neutral switch provides an input to the Powertrain Control Module (PCM). The park/neutral position switch is located on the automatic transaxle housing Fig. 20. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. CIRCUIT OPERATION When CLOSED the Transmission Range Switch (TRS) provides an input to the Powertrain Control Module (PCM) on circuit T41. This circuit connects to cavity 76 of the PCM connector. The T41 circuit is spliced and provides a ground path for the engine starter relay, and the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Mounting Bolt 2.2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 700 Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 703 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 704 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 705 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 706 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 707 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 708 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 709 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 710 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 711 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 712 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 713 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 714 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 715 Vehicle Speed Sensor: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 716 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 717 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 718 Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > System Operation Vehicle Speed Sensor: Description and Operation System Operation SYSTEM OPERATION The Vehicle Speed Sensor (VSS) is a pulse generator mounted to an adapter near the transmission output shaft. The sensor is driven through the adapter by a speedometer pinion gear. The VSS pulse signal to the speedometer/odometer is monitored by the PCM speed control circuitry to determine vehicle speed and to maintain speed control set speed. Refer to the Powertrain Management/Computer and Control Systems/Diagnostic Procedures for diagnosis and testing of this component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > System Operation > Page 721 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor-PCM Input Fig. 17 Vehicle Speed Sensor -- Automatic Transmission Fig. 18 Vehicle Speed Sensor -- Manual Transmission PURPOSE The sensor input is used by the PCM to determine vehicle speed and distance traveled. OPERATION The vehicle speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a closed throttle signal from the throttle position sensor, indicate a closed throttle deceleration to the PCM. Under deceleration conditions, the PCM adjusts the Idle Air Control (IAC) motor to maintain a desired MAP value. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. The vehicle speed sensor signal is also used to operate: Speedometer - Speed control - Daytime Running Lights (Canadian Vehicles only). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the Vehicle Speed Sensor (VSS). The K7 circuit connects to cavity 44 of the PCM connector. Circuit G7 from the VSS provides an input signal to the PCM. The G7 circuit connects to cavity 66 of the PCM connector. The PCM provides ground for the VSS signal (circuit G7) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Helpful Information Vehicle Speed Sensor: Testing and Inspection Helpful Information Circuit G7 splices to the speedometer and odometer in the instrument cluster. Circuit K7 splices to supply 8 Volts to the camshaft position sensor and crankshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 724 Vehicle Speed Sensor: Service and Repair Fig. 24 Vehicle Speed Sensor Fig. 7 Vehicle Speed Sensor And Connector Fig. 8 Vehicle Speed Sensor And Speedometer Pinion Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 725 NOTE: The vehicle speed sensor is located in the transmission extension housing (Fig. 24). REMOVAL 1. Disconnect electrical connector from sensor. 2. Remove the sensor mounting bolt. 3. Lift the sensor out of the transaxle extension housing. Ensure the 0-ring was removed with the sensor. NOTE: The speed sensor gear meshes with a gear on the output shaft. INSTALLATION 1. With 0-ring in place, install sensor and seat sensor by hand -- to ensure proper gear engagement. 2. Install mounting bolt and torque bolt to 2.2 Nm (20 in lb). 3. Connect electrical connector to sensor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 731 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 732 Throttle Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 733 Throttle Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 734 Throttle Position Sensor: Description and Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS mounts to the throttle body and connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- from 0.38 to 1.03 volts. - AT Wide open throttle -- 3.1 to 4.0 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). CIRCUIT OPERATION From the Powertrain Control Module (PCM) circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 737 Throttle Position Sensor: Testing and Inspection Component Testing To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool and follow the appropriate procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for correct pinout. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 738 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 739 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (20 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis > Page 745 Camshaft Position Sensor: Technical Service Bulletins Cam/Crank Sensor - No Start Diagnostics NO: 18-24-97 GROUP: Vehicle Performance DATE: Aug. 8, 1997 SUBJECT: No Start Diagnostics Cam/Crank Sensor $01 and $28 MODELS: 1997 (FJ) Avenger/Sebring/Talon 1997 (GS) Chrysler Voyager (International Market) 1997 (JA) Breeze/Cirrus/Stratus 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1997 (NS) Town & Country/Caravan/Voyager 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L DOHC/SOHC (NATURALLY ASPIRATED), 2.4L, 3.3L, 3.5L, OR 3.8L ENGINE. DISCUSSION: If a vehicle exhibits a no-start due to failure of the cam or crank sensor, the opposite sensor may be reported as the DTC (i.e. bad cam sensor sets crank sensor DTC and vice versa). The faulty sensor may generate a signal strong enough (at key "ON") to be interpreted by the controller as a legitimate signal. Since the engine is not running, the opposite sensor will not be generating any pulses. The controller, expecting corresponding pulses from both sensors, matures a fault for the sensor that is not generating any pulses. In this case, the good sensor is reported as faulty. To verify which sensor is at fault, use the DRB III and select DRB III Standalone, 1994 - 1998 Diagnostics, select Engine system, select Monitor Display, and No Start monitor. Under the No Start monitor the cam and crank sensors should display a no response or LOST on the display. If a sensor is reporting a signal at key ON", it should be replaced. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 748 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 749 Camshaft Position Sensor: Locations Camshaft Position Sensor Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 750 Camshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 751 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity OPERATION The camshaft position sensor attaches to the rear of the cylinder head. A target magnet attaches to the rear of the camshaft and indexes to the Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 752 correct position. The target magnet has four different poles arranged in an asymmetrical pattern (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the camshaft position sensor The K7 circuit connects to cavity 44 of the PCM connector. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 33 of the PCM connector. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing Camshaft Position Sensor: Testing and Inspection Component Testing The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting an oscilloscope and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing > Page 755 Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing > Page 756 Camshaft Position Sensor: Testing and Inspection Failure to Start Test Fig.20 Ignition Coil Engine Harness Connector This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Sensor Replacement Camshaft Position Sensor Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head. REMOVAL 1. Remove filtered air tube from the throttle body and air cleaner housing. 2. Disconnect electrical connector from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.35 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft (Fig. 35). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 759 Fig.36 Target Magnet Installation NOTE: The target magnet has locating dowels that fit into machined locating holes in the end of the camshaft (Fig. 36). INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install filtered air tube. Tighten clamps to 3 Nm ±1 (25 in lb ±5) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 760 Camshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Cam/Crank Sensor - No Start Diagnostics Crankshaft Position Sensor: Technical Service Bulletins Cam/Crank Sensor - No Start Diagnostics NO: 18-24-97 GROUP: Vehicle Performance DATE: Aug. 8, 1997 SUBJECT: No Start Diagnostics Cam/Crank Sensor $01 and $28 MODELS: 1997 (FJ) Avenger/Sebring/Talon 1997 (GS) Chrysler Voyager (International Market) 1997 (JA) Breeze/Cirrus/Stratus 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1997 (NS) Town & Country/Caravan/Voyager 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L DOHC/SOHC (NATURALLY ASPIRATED), 2.4L, 3.3L, 3.5L, OR 3.8L ENGINE. DISCUSSION: If a vehicle exhibits a no-start due to failure of the cam or crank sensor, the opposite sensor may be reported as the DTC (i.e. bad cam sensor sets crank sensor DTC and vice versa). The faulty sensor may generate a signal strong enough (at key "ON") to be interpreted by the controller as a legitimate signal. Since the engine is not running, the opposite sensor will not be generating any pulses. The controller, expecting corresponding pulses from both sensors, matures a fault for the sensor that is not generating any pulses. In this case, the good sensor is reported as faulty. To verify which sensor is at fault, use the DRB III and select DRB III Standalone, 1994 - 1998 Diagnostics, select Engine system, select Monitor Display, and No Start monitor. Under the No Start monitor the cam and crank sensors should display a no response or LOST on the display. If a sensor is reporting a signal at key ON", it should be replaced. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 767 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position Sensor Bolts ........................................................................................................ .......................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 768 Fig 7 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 769 Crankshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 770 Crankshaft Position Sensor: Description and Operation Fig 7 Crankshaft Position Sensor Fig. 14 Timing Reference Notches Fig.6 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60° signature notch (Fig. 14). The notches generate pulses from high to low in the crankshaft position sensor output voltage. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 771 - When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69° before top dead center (BTDC). - The second notch represents 49° BTDC. - The third notch represents 29°. - The last notch in each set represents 9° before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM connector. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test Fig.20 Ignition Coil Engine Harness Connector This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 774 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig 7 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Crankshaft Position Sensor Bolts torque ....................................................................................................................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 777 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation SYSTEM OPERATION Ignition Lock Cylinder Detents The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detents: - Accessory - Off (lock) - Unlock - On/Run - Start Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 782 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Detentes The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detentes: Accessory - Off (lock) - Unlock - On/Run - Start REMOVAL 1. Disconnect negative cable from battery. 2. Place key cylinder in RUN position. - Through the hole in the lower shroud, depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. - Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. - To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. - Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Connect negative cable to battery Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 786 Knock Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 787 Knock Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 788 Knock Sensor: Description and Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 24 of the PCM connector. The PCM provides ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Helpful Information Knock Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 791 Knock Sensor: Testing and Inspection Component Testing The knock sensor can be tested with a digital voltmeter. Sensor output should be between 80 mV and 4 volts with the engine running between 576 and 2,208 rpm. If the output falls outside of this range a DTC will be set. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Page 792 Knock Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 798 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 799 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 800 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 801 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 802 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 803 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 804 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 805 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 806 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 808 PARTS REQUIRED: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 809 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 810 POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations The airbag control module (ACM) is an electronic module that monitors the airbag system for proper operation, stores diagnostic trouble code (DTCs), controls the airbag warning lamp, and contains the safing sensor and accelerometer that is responsible for airbag deployment. The ACM is located on the floor pan between the gear shifter and the parking brake assembly. The ACM provides diagnostic information (DTCs) to the technician through the DRB Ill via the CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. NOTE: The warning lamp is hardwired to the ACM and there are no external impact sensors. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Service Precautions Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Service Precautions > Page 818 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature. This temperature data, along with data from monitored line voltage, is used by the (PCM) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Battery Temperature Sensor The sensor is located forward of the vehicle battery, and is attached to the battery tray. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to Powertrain Management/Computer and Controls/Testing and Inspection. 1. The sensor is located under the battery and is attached to the battery tray. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25 °C (75-80 °F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) Ohms should be observed. 5. If reading is above or below the specification, replace the sensor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 821 Battery Temperature Sensor: Service and Repair REMOVE 1. Make sure ignition switch is in OFF position and all accessories are OFF. Disconnect Battery Negative Cable 2. Remove battery negative cable first then the positive cable. Battery Thermoguard 3. Remove battery thermoguard. WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN. Air Inlet Tube Pull Strap Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 822 4. Remove temperature sensor mounting nut from battery tray. Battery Temperature Sensor Connector 5. Disconnect sensor wire connector. INSTALL - For installation reverse above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation The clutch pedal position switch functions as a safety interlock device. It prevents possible engine cranking with the clutch engaged. The clutch pedal position switch is wired in series between the starter relay coil and the ignition switch. The clutch pedal position switch is mounted to a bracket located behind the clutch pedal. The switch is held in place by four plastic wing tabs. The clutch pedal position switch IS NOT adjustable. The pedal blade contacts the switch in the down position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation > Page 826 Clutch Switch: Testing and Inspection ELECTRICAL TEST Disconnect clutch pedal position switch harness from instrument panel wiring harness. Using an ohmmeter, check for continuity between the two terminals in the connector on the switch harness. There should be no continuity between the terminals when the switch is in its normal (fully extended) position. When the switch is depressed more than 1.25 mm (0.050 inch), the ohmmeter should show continuity (zero ohms). If ohmmeter readings do not fall within these ranges, the switch is defective, and must be replaced. MECHANICAL TEST With the park brake set and the vehicle IN NEUTRAL, turn the key to the start position. The vehicle should not crank. If the vehicle cranks, the switch is defective (shorted out) and must be replaced. If the vehicle does not crank proceed to the next step. WARNING: Before performing this step, be sure that the area in front of the vehicle is clear of obstructions and people. Vehicle may move when performing this test. With the park brake set and the vehicle IN GEAR, turn the key to the start position and hold it there. Slowly depress the clutch pedal and feel for any vehicle motion when the starter is energized. If there is no motion the switch is working properly. If motion is felt, check to see if the switch is making contact when the pedal is between 25 mm (1.0 inch) and 6 mm (0.25 inch) from the floor. If this condition is met, then the problem is either the clutch or the self-adjusting cable. If this condition is not met, then the switch mounting tab on the brake bracket is bent, and the brake bracket must be replaced. If vehicle will not crank, even with clutch pedal pressed to the floor, refer to illustrated chart. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation > Page 827 Clutch Switch: Adjustments The clutch pedal position switch is mounted to a bracket located behind the clutch pedal. The switch is held in place by four plastic wing tabs. The clutch pedal position switch IS NOT adjustable. The pedal blade contacts the switch in the down position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation > Page 828 Clutch Switch: Service and Repair NOTES: ^ The clutch pedal position switch is mounted to a bracket located behind the clutch pedal. The switch is held in place by four plastic wing tabs. ^ The clutch pedal position switch IS NOT adjustable. The pedal blade contacts the switch in the down position. REMOVAL 1. Disconnect electrical harness to switch connector. 2. Depress wing tabs on switch and push switch out of mounting bracket. Then slide wires through slot in bracket. INSTALLATION 1. Slide switch wires through slot in switch bracket. 2. Line up switch tab with slot in switch bracket and push switch into position. Do not pull on the switch wires to seat switch into bracket, switch damage may occur. 3. Attach switch wiring harness to vehicle wiring harness. 4. After installation, the switch must be checked for proper operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation SYSTEM OPERATION Ignition Lock Cylinder Detents The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detents: - Accessory - Off (lock) - Unlock - On/Run - Start Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 833 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Detentes The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detentes: Accessory - Off (lock) - Unlock - On/Run - Start REMOVAL 1. Disconnect negative cable from battery. 2. Place key cylinder in RUN position. - Through the hole in the lower shroud, depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. - Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. - To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. - Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Connect negative cable to battery Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 34 Nm (25 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 837 Neutral Safety Switch: Testing and Inspection The park/neutral starting switch is the center terminal of the three terminal switch. It provides ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 838 Neutral Safety Switch: Service and Repair REMOVAL Unscrew switch from transaxle case allowing fluid to drain into a container. Move selector lever to PARK, then to NEUTRAL position, and inspect to see the switch operating lever fingers are centered in switch opening. INSTALLATION 1. Screw the switch with a new seal into transaxle case and tighten to 33 Nm (24 ft. lbs.). Retest switch with the test lamp. 2. Add fluid to transaxle to bring up to proper level. 3. The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 4. To test switch, remove wiring connector from switch and test for continuity between the two outside pins. 5. Continuity should exist only with transaxle in REVERSE position. 6. No continuity should exist from either pin to the case. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 845 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 846 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 847 Power Steering Pressure Switch: Description and Operation Fig. 15 Power Steering Pressure Switch PURPOSE On vehicles equipped with power steering, a power steering pressure switch is used to improve the vehicle's idle quality. The pressure switch improves vehicle idle quality, by controlling engine idle speed when required. The switch (Fig. 15) provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. OPERATION The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed is increased. This increase in engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. When power steering pump pressure exceeds 2,758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. The power steering pressure switch is mounted directly to the power steering gear on vehicles requiring its usage. CIRCUIT OPERATION The power steering pressure switch opens and closes circuit K10 between the Powertrain Control Module (PCM) and ground. Circuit K10 connects to cavity 45 of the PCM connector. Circuit Z12 provides ground for the power steering pressure switch. The grounding point for circuit Z12 is the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 848 Power Steering Pressure Switch: Service and Repair CAUTION: When removing and installing the power steering pressure switch, the use of a 7/8 inch deep well socket is required. The deep well socket will prevent damage to the plastic, electrical connector area, of the power steering pressure switch. REMOVE 1. Disconnect negative battery cable from the negative post of the battery. Be sure cable is isolated from negative post on battery. 2. Raise vehicle. 3. Locate power steering pressure switch on back side of power steering gear. 4. Remove vehicle wiring harness connector, from power steering pressure switch. 5. Remove power steering pressure switch, from power steering gear. CAUTION: When tightening the power steering pressure switch after installation in steering gear, do not exceed the torque specification shown in step 1 below. Over-tightening may result in stripping the threads out of the pressure switch port on the steering gear. INSTALL 1. Install power steering pressure switch into power steering gear by hand until fully seated. Then torque power steering pressure switch to 8 Nm (70 inch lbs.). 2. Install vehicle wiring harness connector onto power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with locking tab on power steering pressure switch. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar (R), Power Steering Fluid, or equivalent. 3. Fill power steering reservoir to correct fluid level. 4. Connect negative cable back on negative post of battery. 5. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Throttle Position Sensor Mounting Screws 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 854 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 855 Transmission Position Switch/Sensor: Description and Operation Fig. 20 Park/Neutral Switch OPERATION On vehicles with 3-speed automatic transmission the park/neutral switch provides an input to the Powertrain Control Module (PCM). The park/neutral position switch is located on the automatic transaxle housing Fig. 20. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. CIRCUIT OPERATION When CLOSED the Transmission Range Switch (TRS) provides an input to the Powertrain Control Module (PCM) on circuit T41. This circuit connects to cavity 76 of the PCM connector. The T41 circuit is spliced and provides a ground path for the engine starter relay, and the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation Heated Glass Element Switch: Description and Operation SYSTEM OPERATION The rear window defogger switch is a control switch and timer relay integrated into a single panel mounted assembly. Actuating the switch energizes the circuit which allows current to flow through the grid lines. Upon initial actuation for approximately eight to ten minutes, or until either the switch or ignition is turned off. An indicating lamp illuminates a lens inlaid in the control switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Page 860 Heated Glass Element Switch: Testing and Inspection The rear window defogger switch may be tested in- vehicle or bench tested. In vehicle testing is accomplished in the following manner: 1. Remove the switch from the instrument panel but leave the switch connected. 2. Turn the ignition switch ON. Rear Window Defogger Switch Rear Window Defogger Switch-Export 3. Using a voltmeter, check for battery voltage at Pin 3 and Pin 4. a. If OK, go to Step 4. b. If NOT OK, check fuse 8 in fuse block and the 30 Amp maxi fuse in the Power Distribution Center (PDC). If fuses are OK, check wiring circuit. 4. Check Pin 5, with switch in the ON position there should be battery voltage and no voltage in the OFF position. a. If OK, go to Step 5. b. If NOT OK, no voltage in the ON position or voltage in the OFF position. Replace the switch/relay module. 5. Press switch to ON position. The indicator lamp should come on and remain on for approximately 10 minutes. If the indicator lamp fails to light or no voltage is present for approximately 10 minutes. Replace Rear Window Defogger Switch. 6. To bench test relay: a. Using a jumper wire connect a 12 volt batter supply, apply voltage to Pin 3 and 4. Ground Pin 2. b. Follow the above procedures except Step 2 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation Power Window Switch: Description and Operation CIRCUIT OPERATION Master Window Switch (Left Window Operation) When the window switch is moved to the window DOWN position, voltage is supplied on the F21 circuit through the CLOSED contacts in the switch to the Q21 circuit. The Q21 circuit connects from the switch to the left front window motor. Grounding is provided on circuit Q11 from the motor back to the switch. The ground is passed through the switch to the Z8 circuit. The Z8 circuit goes to its grounding point. When window UP operation is selected, the power and ground circuits are reversed. Circuit Q11 is the feed and circuit Q21 is the ground. Master Window Switch (Right Window Operation) When the window switch is moved to the window DOWN position, voltage is supplied on the F21 circuit through the CLOSED contacts in the switch to the Q26 circuit. The Q26 circuit connects from the master switch to the right window switch. A BUS bar internal to the right switch passes the voltage through the switch to circuit Q22. Circuit Q22 connects from the switch to the right window motor. Grounding is provided on circuit Q12 from the motor back to the right switch. The ground is passed through the switch on a BUS bar to circuit Q16. Circuit Q16 then goes to the master switch. The ground is passed through the switch to the Z8 circuit. The Z8 circuit attaches to its grounding point. When window UP operation is selected, the power and ground circuits are reversed. Circuits Q12 and Q16 are the feeds and circuits Q22 and Q26 are the grounds. Right Window Switch Operation When the window switch is moved to the window DOWN position, voltage is supplied on the F21 circuit through the CLOSED contacts in the switch to the Q22 circuit. The Q22 circuit connects from the switch to the right front window motor. Grounding is provided on circuit Q12 from the motor back to the switch. The ground is passed through the switch to the Q16 circuit. The Q16 circuit connects from the right switch to the master switch. Ground is passed through the master switch to the Z8 circuit. The Z8 circuit goes to its grounding point. When window UP operation is selected, the power and ground circuits are reversed. Circuit Q12 is the feed and circuit Q22 is the ground. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Helpful Information Power Window Switch: Testing and Inspection Helpful Information - Check the 40 Amp fuse located in the PDC. - Check the 30 Amp circuit breaker located behind the fuse block. - Check the ground at the instrument panel left center support. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Helpful Information > Page 866 Power Window Switch: Testing and Inspection Power Window Switch Test Driver Side Window Switch Continuity Test Passenger Side Window Switch Continuity Test Remove the switch from its mounting, refer to the Window Switch Removal and Installation procedures. Using an ohmmeter, refer to the test procedure, Driver Side or Passenger Side Window Switch Continuity Test to determine if continuity is correct. If the results are not obtained, replace the switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 867 Power Window Switch: Service and Repair REMOVAL Switch Removal 1. Using a flat tool, insert tool in the slot on the bottom of the switch bezel. 2. Pry the bezel from the door trim panel. 3. Disconnect wire connector from switch. 4. Remove switch by releasing the tabs from bezel. INSTALLATION - For installation, reverse above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection Wiper Switch: Testing and Inspection Wiper Switch Test To test the switch, first disconnect the switch wires from the body wiring in the steering column. Using an ohmmeter, test for continuity between the terminals of the switch, as indicated. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 872 Wiper Switch: Service and Repair REMOVAL Upper Shroud Removal 1. Remove three screws holding steering column shroud and remove upper half of shroud. 2. Remove mounting screw on switch and remove switch. 3. Disconnect wire harness connector from switch. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration Alignment: Customer Interest Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 882 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 883 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration Alignment: All Technical Service Bulletins Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 889 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 890 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment Alignment: All Technical Service Bulletins Alignment & Suspension - Specifications & Adjustment NO: 02-04-97 GROUP: Suspension DATE: May 16, 1997 SUBJECT: Front End Alignment Torque Specifications & Shock Adjustment Procedures On Competition Package MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH THE COMPETITION PACKAGE SALES CODE (ACR) SUSPENSION SALES CODE (SDK). DISCUSSION: The alignment on ACR equipped vehicles must be set to the preferred specifications provided in the 1997 Neon Service Manual (Publication Number 81-270-7025) page 2-7. After each final setting the nuts should then be torqued to 75 ft.lbs plus an additional 90 degree turn. It is important that the proper torque be used to maintain the proper alignment. If the alignment is outside of specifications, rapid and excessive tire wear will result. Starting in 1997, Neon competition package (ACR) vehicles come equipped with adjustable strut dampers on all four wheels. The struts are finely tuned to the ride and handling profile of the entire suspension system. If the customer wishes to change the dampening force for special conditions the dampening characteristics of the strut dampers are adjustable on the ACR equipped vehicles. The knob for adjusting the strut can be found in a packet located in the glove compartment. The adjustment procedures are as follows: 1. The top end of the adjusting rod has flats over which the adjusting knob will fit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment > Page 895 2. Install the knob over the top end of the front or rear damper and lock it into position by turning counterclockwise slowly until the knob engages, (Illustration). 3. Turn the adjusting knob clockwise, if resistance is felt do not use force, as the damper is in an unadjusted position. Reverse the adjustment slightly and try again. When the damper is in the full clockwise position, this is the minimum (City Ride) position. 4. To adjust the dampening force, the adjusting knobs has to be turned in the direction of the arrow for increased dampening and the opposite direction for decreased dampening. NOTE: BOTH THE LEFT AND RIGHT STRUT DAMPERS MUST BE ADJUSTED IDENTICALLY. FAILURE TO DO SO COULD PRODUCE UNSTABLE HANDLING AND UNEVEN TIRE TREAD WEAR. 5. The following is a description of the various settings and the adjustment procedure. A. City Ride - To enjoy the most comfortable city ride, the struts should be left in the "minimum" position as they are set from the assembly plant. To set to minimum the knob should be turned completely clockwise. B. Cross Country - The cross country setting will give the car a firmer handling characteristic, but yet will still be very comfortable to drive. To set, turn the adjusting knob 1/2 turn counter clockwise from the "minimum" position. C. G.T./Aggressive Driving - This setting equates the car's handling to a cross-country grand turismo car, offering increased cornering ability, improved road feel and precise directional stability at higher speeds. To set turn the adjusting knob 1 turn counter clockwise from the "minimum" position. 6. Remove the adjusting knob before closing the hood or trunk. The vehicle should not be driven with the adjusting knob in place. NOTE: DURING INSPECTION/SERVICING A THIN FILM OF OIL AND DUST COLLECTION MAY BE NOTICED ON THE OUTSIDE OF THE STRUT TUBE. THIS IS A NORMAL CONDITION WHICH OCCURS DURING THE DAMPER INTERNAL SEAL "BREAK-IN" PERIOD AND DOES NOT AFFECT THE PERFORMANCE OF THE STRUT AND DOES NOT INDICATE THE NEED FOR STRUT REPLACEMENT. STRUT REPLACEMENT SHOULD ONLY OCCUR IF THE STRUT LEAKAGE IS SUFFICIENT TO COVER THE ENTIRE STRUT DAMPER TUBE AND HAS "DRIPPED" ONTO THE LOWER CONTROL ARM OR ONTO THE PAVEMENT DURING OVERNIGHT PARKING. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 26-12-96D > Dec > 96 > Steering/Suspension - Alignment Specifications Revisions Alignment: All Technical Service Bulletins Steering/Suspension - Alignment Specifications Revisions NUMBER: 26-12-96D GROUP: Miscellaneous DATE: December, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Neon - Publication Number 81-270-7025 DESCRIPTION OF CHANGES Revision the front end alignment specifications Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 26-12-96D > Dec > 96 > Steering/Suspension - Alignment Specifications Revisions > Page 900 2-7 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment Alignment: All Technical Service Bulletins Alignment & Suspension - Specifications & Adjustment NO: 02-04-97 GROUP: Suspension DATE: May 16, 1997 SUBJECT: Front End Alignment Torque Specifications & Shock Adjustment Procedures On Competition Package MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH THE COMPETITION PACKAGE SALES CODE (ACR) SUSPENSION SALES CODE (SDK). DISCUSSION: The alignment on ACR equipped vehicles must be set to the preferred specifications provided in the 1997 Neon Service Manual (Publication Number 81-270-7025) page 2-7. After each final setting the nuts should then be torqued to 75 ft.lbs plus an additional 90 degree turn. It is important that the proper torque be used to maintain the proper alignment. If the alignment is outside of specifications, rapid and excessive tire wear will result. Starting in 1997, Neon competition package (ACR) vehicles come equipped with adjustable strut dampers on all four wheels. The struts are finely tuned to the ride and handling profile of the entire suspension system. If the customer wishes to change the dampening force for special conditions the dampening characteristics of the strut dampers are adjustable on the ACR equipped vehicles. The knob for adjusting the strut can be found in a packet located in the glove compartment. The adjustment procedures are as follows: 1. The top end of the adjusting rod has flats over which the adjusting knob will fit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment > Page 906 2. Install the knob over the top end of the front or rear damper and lock it into position by turning counterclockwise slowly until the knob engages, (Illustration). 3. Turn the adjusting knob clockwise, if resistance is felt do not use force, as the damper is in an unadjusted position. Reverse the adjustment slightly and try again. When the damper is in the full clockwise position, this is the minimum (City Ride) position. 4. To adjust the dampening force, the adjusting knobs has to be turned in the direction of the arrow for increased dampening and the opposite direction for decreased dampening. NOTE: BOTH THE LEFT AND RIGHT STRUT DAMPERS MUST BE ADJUSTED IDENTICALLY. FAILURE TO DO SO COULD PRODUCE UNSTABLE HANDLING AND UNEVEN TIRE TREAD WEAR. 5. The following is a description of the various settings and the adjustment procedure. A. City Ride - To enjoy the most comfortable city ride, the struts should be left in the "minimum" position as they are set from the assembly plant. To set to minimum the knob should be turned completely clockwise. B. Cross Country - The cross country setting will give the car a firmer handling characteristic, but yet will still be very comfortable to drive. To set, turn the adjusting knob 1/2 turn counter clockwise from the "minimum" position. C. G.T./Aggressive Driving - This setting equates the car's handling to a cross-country grand turismo car, offering increased cornering ability, improved road feel and precise directional stability at higher speeds. To set turn the adjusting knob 1 turn counter clockwise from the "minimum" position. 6. Remove the adjusting knob before closing the hood or trunk. The vehicle should not be driven with the adjusting knob in place. NOTE: DURING INSPECTION/SERVICING A THIN FILM OF OIL AND DUST COLLECTION MAY BE NOTICED ON THE OUTSIDE OF THE STRUT TUBE. THIS IS A NORMAL CONDITION WHICH OCCURS DURING THE DAMPER INTERNAL SEAL "BREAK-IN" PERIOD AND DOES NOT AFFECT THE PERFORMANCE OF THE STRUT AND DOES NOT INDICATE THE NEED FOR STRUT REPLACEMENT. STRUT REPLACEMENT SHOULD ONLY OCCUR IF THE STRUT LEAKAGE IS SUFFICIENT TO COVER THE ENTIRE STRUT DAMPER TUBE AND HAS "DRIPPED" ONTO THE LOWER CONTROL ARM OR ONTO THE PAVEMENT DURING OVERNIGHT PARKING. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 26-12-96D > Dec > 96 > Steering/Suspension - Alignment Specifications Revisions Alignment: All Technical Service Bulletins Steering/Suspension - Alignment Specifications Revisions NUMBER: 26-12-96D GROUP: Miscellaneous DATE: December, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Neon - Publication Number 81-270-7025 DESCRIPTION OF CHANGES Revision the front end alignment specifications Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 26-12-96D > Dec > 96 > Steering/Suspension - Alignment Specifications Revisions > Page 911 2-7 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 912 Alignment: By Symptom Technical Service Bulletin # 02-09-99 Date: 990702 Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 913 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 914 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Technical Service Bulletin # 02-09-99 Date: 990702 Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 915 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 916 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 917 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 918 Alignment: Specifications The content of this article reflects changes called for in TSB 26-12-96. NOTE: All alignment specifications are taken at curb height. FRONT: Camber: Acceptable Range ................................................................................................................ ........................................................................ -0.4° to +0.4° Preferred Setting .................................. .............................................................................................................................................................. .......... 0.0° S/C ACR only [3] ............................................................................................................... .......................................................................... -2.4° to +0.4° Total Toe [1]: Acceptable Range ......................................................................................................... ........................................................................ 0.3° in to 0.1° out Preferred Setting ............................ .............................................................................................................................................................. ............ 0.1° in S/C ACR only [3] ......................................................................................................... ................................................................... 0.30° In to 0.70° Out Caster*: Acceptable Range ................................................................................................................. ....................................................................... +1.8° to +3.8° Preferred Setting .................................. .............................................................................................................................................................. ........ +2.8° * Side To Side Caster: Not To Exceed ................................................................................................ ................................................................................................. 1.0° or less REAR: Camber: Acceptable Range ................................................................................................................ .................................................................... -0.75° to +0.25° Preferred Setting .................................. .............................................................................................................................................................. ....... -0.25° S/C ACR only [3] ............................................................................................................... ...................................................................... -1.00° to +0.25° Total Toe [1] [2]: Acceptable Range .................................................................................................... .............................................................................. 0.3° in to 0.1°out Preferred Setting ....................... .............................................................................................................................................................. ................. 0.1° in S/C ACR only [3] .................................................................................................... ........................................................................ 0.30° In to 0.50° Out Thrust Angle ........................................................................................................................................ .................................................... -0.10° to +0.10° [1]: Total toe is the arithmetic sum of the left and right wheel toe settings. Positive is toe-in, negative is toe-out. Total toe must be equally split between each front wheel to ensure the steering wheel is centered after setting toe. Left and right toe must be equal to within 0.02 degrees. [2]: Toe-out when backed on to the alignment rack is toe in when driving. [3]: The alignment specifications shown, are only for vehicles which are equipped with the ACR (Competition Package) sales code. This specification is listed to show the adjustable range for the Camber and Toe on the front and rear suspension of a vehicle with the Competition Package. These alignment specifications are only to be used at the request of the vehicle owner and only when the vehicle is going to be used in a competition event. The alignment is to be set back to the preferred setting before the vehicle is returned to normal operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 919 Alignment: Service Precautions CAUTION: Do not attempt to modify any suspension or steering components by heating or bending of the component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 920 Alignment: Description and Operation GENERAL INFORMATION Proper vehicle wheel alignment is the proper adjustment of all interrelated front and rear suspension angles. These angles are what affects the handling and steering of the vehicle when it is in motion. The method of checking a vehicle's front and rear wheel alignment will vary depending on the type and manufacturer of the equipment being used. Instructions furnished by the manufacturer of the equipment being used should always be followed to ensure accuracy of the alignment, except alignment specifications recommended by Chrysler Corporation MUST ALWAYS be used. CAUTION: Do not attempt to modify any suspension or steering components by heating or bending of the component. ORDER OF ADJUSTMENTS Wheel alignment adjustments should be made in the following sequence, to ensure that an accurate alignment is performed. 1. Rear Wheel Toe Adjustment within specifications for both total toe and thrust angle. 2. Front Wheel Toe Adjustment within specifications for total toe. 3. Toe is measured in degrees or inches and is the distance that the front edges of the tires are closer (or farther apart) than the rear edges. 4. Thrust Angle is defined as the average of the Toe settings on each rear wheel. If this measurement is out of specification, re-adjust rear wheel Toe so that each wheel has 1/2 of the total Toe measurement. When re-adjusting, do not exceed the total Toe specification. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 921 Alignment: Testing and Inspection CAUTION: If the front suspension crossmember shows any sign of impact damage, the steering column to steering gear coupling must be inspected. PRE-ALIGNMENT VEHICLE INSPECTION Before any attempt is made to change or correct the wheel alignment factors, the following inspection and necessary corrections must be made on those parts which influence the steering of the vehicle. 1. Be sure the fuel tank is full when the wheel alignment specifications are checked and or adjusted. A full tank of fuel weighs approximately 75 pounds, if the fuel tank is not full this reduction in weight will affect the curb height of the vehicle and the alignment specifications. 2. Alignment specifications of a vehicle can be the most accurately checked and set when the passenger compartment and trunk of the vehicle are vacant with the exception of the spare tire. People, luggage, and any other appreciable weight will adversely affect the checking and setting of the camber specification. 3. Check and if required, inflate all of the tires to the recommended air pressure. All tires must be of the same size and in good condition and have approximately the same tread wear. Note the type of tread wear on the tire, this will aid in diagnosing problems. 4. Check the front tire and wheel assemblies for radial runout. 5. Before beginning the alignment process, inspect all suspension component fasteners for looseness and/or loss of specified torque. 6. Inspect the lower front ball joints and all steering linkage for looseness and any signs of wear and or damage. 7. Inspect the tie rod ends for looseness and any signs of wear and or damage. 8. Inspect the rubber bushings on all suspension components for signs of wear or deterioration. If any bushings show signs of wear or deterioration they should be replaced prior to aligning the vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber Adjustment Bolt Package Installation Alignment: Service and Repair Camber Adjustment Bolt Package Installation 1. If front and or rear camber readings obtained are not within the required specification range, a Mopar (R) Service Kit is available to provide the required adjustment. The kit contains new bolts and nuts for the strut clevis bracket to steering knuckle attachment. The bolts contained in the service kit, are slightly undersize allowing for movement between the strut clevis bracket and steering knuckle. The movement allowed by the undersize bolts will provide approximately 2 degrees of camber adjustment per side of vehicle. To install new bolts in service kit follow the procedure below. CAUTION: The Mopar (R) Service Kit for allowing adjustment of front and rear camber are different for the front and rear of the vehicle. When using the service kits be sure that the front and rear strut attaching bolts are always used in the right location on the vehicle. 2. Raise front and or rear of vehicle until tires are not supporting the weight of the vehicle. CAUTION: The steering knuckle and rear knuckle to strut assembly attaching bolts are serrated and must not be turned during removal. Remove nuts while holding bolts stationary in the steering knuckles. 3. Remove original upper bolt attaching the front or rear strut clevis bracket to the steering knuckle or rear knuckle. 4. Loosen lower bolt attaching strut clevis bracket to steering knuckle or rear knuckle ONLY enough to allow knuckle to move in clevis bracket. 5. Install bolt from service kit into the upper strut clevis bracket to steering knuckle or rear knuckle mounting hole. CAUTION: Only the nuts supplied in the service kits MUST be used with the service kit replacement bolts. The original nuts will not properly secure the strut clevis bracket to steering knuckle or rear knuckle. 6. Install nut provided in service kit on the replacement bolt. 7. Tighten upper bolt and nut from service kit until snug, but still allowing movement between strut clevis bracket and knuckle. 8. Remove original lower bolt. Install bolt from service kit into the bottom hole of the strut clevis bracket. Install nut and snug. 9. Lower vehicle until full weight of vehicle is supported by the suspension and then jounce front and rear of vehicle an equal amount of times. 10. Adjust front and or rear camber to the preferred setting by pushing or pulling on the top of the front or rear tire. When camber is correctly set tighten upper and lower strut clevis bracket bolts. Again jounce front and rear of vehicle an equal amount of times and verify front and rear camber setting. 11. When vehicle is at correct camber setting torque both front strut clevis bracket to steering knuckle attaching bolts to 53 Nm (40 ft. lbs.) plus an additional 1/4 turn after required torque is met. Torque rear strut clevis bracket to rear knuckle attaching bolts to 95 Nm (70 ft. lbs.). 12. If Toe readings obtained are not within the required specification range, adjust Toe to meet the preferred specification setting. Toe is adjustable Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber Adjustment Bolt Package Installation > Page 924 using the following Toe setting procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber Adjustment Bolt Package Installation > Page 925 Alignment: Service and Repair Checking Wheel Alignment Angles GENERAL INFORMATION Front and rear Caster and Camber settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle's suspension components. This is called a Net Build vehicle and results in no required adjustment of Caster and Camber after vehicle is built or when servicing the suspension components. Thus Caster and Camber are not normally considered an adjustable specification when performing an alignment on this vehicle. Though Caster and Camber are not adjustable they must be checked to ensure they meet vehicle specifications. If front and or rear camber is found not to meet the vehicle alignment specifications, it can be adjusted using a Mopar (R) Service Kit developed to allow for camber adjustment. If a vehicle's front or rear camber is found to be outside the specifications, the vehicles suspension components should be inspected for any signs of damage on bending. This must be done before using the Mopar (R) Service Kit for setting camber to meet required specification. If a vehicles caster is not within manufacturers alignment specifications, check for damaged suspension components or body parts. This type of damage can cause component locations to move affecting vehicle alignment. No adjustment can be made for the Caster setting on this vehicle. CAUTION: Do not attempt to adjust the vehicles Caster or Camber by heating, bending or any other modification of the suspension components. PROCEDURE 1. Correctly position vehicle on alignment rack and install all required equipment on vehicle, per the alignment equipment manufacturers specifications. 2. Center the steering wheel and lock in place using a steering wheel clamp. NOTE: Prior to reading each alignment specification, jounce the front and rear of the vehicle an equal number of times. Induce jounce (rear first then front) by grasping center of bumper and jouncing each end of vehicle an equal number of times. Bumper should always be released when vehicle is at the bottom of the jounce cycle. 3. Correctly jounce vehicle and read front and rear alignment settings and compare to vehicle specifications for Camber, Caster and Toe. If front and rear camber readings are within required specifications proceed to step Step 3 in the Front And Rear Toe Setting procedure. If Camber readings are not within specifications refer to step Step 1 in the camber adjustment bolt package installation procedure, for the front and rear Camber adjustment procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber Adjustment Bolt Package Installation > Page 926 Alignment: Service and Repair Front Alignment CAUTION: If the front suspension crossmember shows any sign of impact damage, the steering column to steering gear coupling must be inspected. Before any attempt is made to change or correct the wheel alignment factors, the following inspection and necessary corrections must be made on those parts which influence the steering of the vehicle. 1. Be sure the fuel tank is full when the wheel alignment specifications are checked and or adjusted. A full tank of fuel weighs approximately 75 pounds, if the fuel tank is not full this reduction in weight will affect the curb height of the vehicle and the alignment specifications. 2. Alignment specifications of a vehicle can be the most accurately checked and set when the passenger compartment and trunk of the vehicle are vacant with the exception of the spare tire. People, luggage, and any other appreciable weight will adversely affect the checking and setting of the camber specification. 3. Check and if required, inflate all of the tires to the recommended air pressure. All tires must be of the same size and in good condition and have approximately the same tread wear. Note the type of tread wear on the tire, this will aid in diagnosing problems. 4. Check the front tire and wheel assemblies for radial runout. 5. Before beginning the alignment process, inspect all suspension component fasteners for looseness and/or loss of specified torque. 6. Inspect the lower front ball joints and all steering linkage for looseness and any signs of wear and or damage. 7. Inspect the tie rod ends for looseness and any signs of wear and or damage. 8. Inspect the rubber bushings on all suspension components for signs of wear or deterioration. If any bushings show signs of wear or deterioration they should be replaced prior to aligning the vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber Adjustment Bolt Package Installation > Page 927 Alignment: Service and Repair Front and Rear Toe Setting Procedure 1. Prepare vehicle as described in the Pre-Alignment Vehicle Inspection procedure. 2. Center steering wheel and lock in place using a steering wheel clamp. 3. When performing the Toe setting procedure, set rear wheel Toe to preferred specification first, then set front wheel Toe to the preferred specification. 4. Loosen nuts on attaching bolts, for the left and right rear lateral links to rear crossmember. 5. Rotate lateral link adjustment cams until the preferred rear Toe specification is obtained. 6. While holding Toe adjustment cams from turning, tighten left and right lateral links to rear crossmember attaching bolt nuts. This will securely hold adjustment cams in position. Then while holding lateral link attaching bolt and adjustment cam from turning, torque nut of lateral link attaching bolt to 95 Nm (70 ft. lbs.). CAUTION: Do not twist front inner tie rod to steering gear rubber boots during front wheel Toe adjustment. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber Adjustment Bolt Package Installation > Page 928 7. Loosen inner to outer tie rod end jam nuts. Grasp inner tie rods at serrations and rotate tie rods to set the front wheel Toe to the preferred specification. 8. Tighten tie rod locknuts to 54 Nm (40 ft. lbs.) torque. 9. Adjust steering gear to tie rod boots at tie rod. 10. Remove steering wheel clamp. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber Adjustment Bolt Package Installation > Page 929 Alignment: Service and Repair Order of Adjustments Wheel alignment adjustments should be made in the following sequence, to ensure that an accurate alignment is performed. 1. Rear Wheel Toe Adjustment within specifications for both total toe and thrust angle. 2. Front Wheel Toe Adjustment within specifications for total toe. 3. Toe is measured in degrees or inches and is the distance that the front edges of the tires are closer (or farther apart) than the rear edges. 4. Thrust Angle is defined as the average of the Toe settings on each rear wheel. If this measurement is out of specification, re-adjust rear wheel Toe so that each wheel has 1/2 of the total Toe measurement. When re-adjusting, do not exceed the total Toe specification. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Typical -- SOHC Shown Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle Odometer <= 1,000 Miles ................................................................................ ............................................................................................. 550 - 1,300 rpm Odometer >= 1,000 Miles .................................................................................................................................................... ......................... 600 - 1,300 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 938 Idle Speed: Testing and Inspection Fig. 31 PCV Vacuum Nipple 1. Turn ignition key off. 2. Disconnect the PCV valve hose from the intake manifold nipple (Fig. 31). Cap the PCV vacuum nipple. Fig. 32 Purge Hose 3. Disconnect purge hose from the nipple on the throttle body (Fig. 32). Fig. 33 Orifice 6457 Attached To Purge Nipple 4. Use a piece of hose to attach Air Metering Orifice 6457 (0.125 in. orifice) or equivalent, to the purge nipple on the throttle body (Fig. 33). 5. Ensure that all accessories are off. 6. Connect the DRB or equivalent scan tool to the data link connector inside the passenger compartment. 7. Run engine in Park or Neutral until the cooling fan has cycled on and off at least once (180°F). 8. Using the DRB or equivalent scan tool, access Minimum Airflow Idle Speed. 9. The following will then occur: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 939 - Idle air control motor will fully close - Idle spark advance will become fixed - PCM will go open loop enriched - DRB or equivalent scan tool displays engine RPM 10. If idle RPM is within the range shown below, throttle body minimum airflow is set correctly. Odometer Reading Idle RPM Below 1,000 Miles 550 - 1,300 RPM Above 1,000 Miles 600 - 1,300 RPM 11. If idle RPM is above specifications, use the DRB or equivalent scan tool to check idle air control motor operation. If idle air control motor is OK, replace throttle body. If idle air flow is below specification, shut off the engine and clean the throttle body as follows: a. Remove the throttle body from engine. WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves, do not let Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash thoroughly after using cleaner. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when is closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 14. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 12. Shut off engine. 13. Remove Air Metering Orifice 6457 or equivalent. Install purge hose. 14. Remove cap from PCV valve. Connect hose to PCV valve. 15. Remove DRB or equivalent scan tool. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Fig. 104 Air Intake Duct Fig. 105 Removal/Installation of Air Inlet Duct NOTE: Neon vehicles do not use a heated air inlet system. The PCM adjusts fuel injector pulse width and ignition timing to compensate for different ambient temperatures. NOTE: The air cleaner attaches to a bracket on the rear of the cylinder head. An ambient air duct supplies underhood air for the engine. REMOVAL 1. Remove air intake tube (Fig. 104) from air cleaner and intake manifold (Fig. 105). Fig. 106 Removal/Installation Air Cleaner Front Housing and Element 2. Tighten clasps on top of air cleaner housing. Rotate front of housing forward then lift front away from air cleaner housing (Fig 106). 3. Remove air cleaner element from front housing (Fig. 106). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 944 INSTALLATION 1. Install air cleaner element into front housing. 2. Rotate front of housing forward then lower into place and locate tabs in slots. - Fasten clasps on top of air cleaner housing. - Install air intake duct at air cleaner and intake manifold. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 949 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 12 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) 6. Replace Pressure test port cap when finished releasing pressure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Cable Routing and Firing Order Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Cable Routing and Firing Order Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum Cables #1 & #4 3,050 Ohms 4,250 Ohms Cables #2 & #3 2,300 Ohms 3,300 Ohms Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 960 Ignition Cable: Description and Operation NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Plastic clips in various locations protect the cables from damage. When the cables are replaced the clips must be used to prevent damage to the cables. The #1 cable must be routed under the PCV hose and clipped to the #2 cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Ignition Cable: Initial Inspection and Diagnostic Overview Fig. 3 Spark Plug Cables NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Be sure that the plastic clip on PCV hose is positioned so that cable clip is beneath hose, and that #1 cable is snapped into this clip to protect it from metal PCV clamp. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 963 Ignition Cable: Component Tests and General Diagnostics Testing For Open Circuits, High Resistance and Loose Terminals Use an ohmmeter to check cables for opens, loose terminals or high resistance as follows: 1. Remove cable from spark plug. 2. Remove cable from the coil tower. 3. Connect the ohmmeter between the spark plug end terminal and the coil end terminal. - Make sure ohmmeter probes are in good contact. - Resistance should be within tolerance shown in the cable resistance chart. - If resistance is not within tolerance, replace cable assembly. Test all spark plug cables in the same manner. - If no problems are found, SEE Ignition System/System Diagnosis/Testing For Spark At Coil. SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum Cables #1 & #4 3,050 Ohms 4,250 Ohms Cables #2 & #3 2,300 Ohms 3,300 Ohms Testing For Punctures and Cracks When testing cables for punctures and cracks with an oscilloscope and an inductive voltage probe, follow the instructions of the equipment manufacturers. CAUTION: Do not leave any one spark plug cable disconnected for more than 30 seconds during test or possible heat damage to catalytic converter will occur. If an oscilloscope and inductive probe are not available, cables can be tested as follows: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. WARNING: The ignition system generates approximately 40,000 volts. Personal injury could result from contact with this system. 2. With the engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). - If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. - Replace cracked, leaking or faulty cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning Ignition Cable: Service and Repair Cleaning Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning > Page 966 Ignition Cable: Service and Repair Replacement Fig. 3 Spark Plug Cables NOTE: The cables insulate the spark plugs and cover the top of the spark plug tube (Fig. 3). CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. REMOVAL 1. Remove spark plug cable from coil first. Lightly grasp the top of the cable. 2. Rotate the insulator 1/2 turn and pull straight up in a steady motion. 3. To replace the cables, disconnect the cable from the ignition coil. INSTALLATION Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube.Then connect the other end to coil pack. Be sure that the plastic clip on PCV hose is positioned so that cable clip is beneath hose, and that #1 cable is snapped into this clip to protect it from metal PCV clamp. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... .......................................................... (0.033-0.038 in) Torque ............................................................ ............................................................................................................................................... 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 970 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ....................................................................... RC9YC Thread Size .................................................... ................................................................................................................................................. (14mm) 3/4 in. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 971 Spark Plug: Description and Operation Resistor spark plugs are used in this engine. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for spark plug diagnosis. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 974 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear - Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 975 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 976 Spark Plug: Testing and Inspection Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 977 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear - Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 978 clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Heavy Colored Deposits DESCRIPTION: Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on the side facing the intake valve. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap, and reinstall .............................................................................................................................................................. .................................................................................... Normal Operating Conditions NORMAL OPERATING CONDITIONS Normal Operation And Cold(Carbon) Fouling The few deposits present will be probably light tan or slightly gray in color with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 1600 km (1000 miles) of operation for non Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 979 platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, have the electrodes filed and regapped, and then reinstalled. CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum spark plugs. This would damage the platinum pads which would shorten spark plug life. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit. The rust color deposits can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Oil or Ash Encrusted OIL OR ASH ENCRUSTED Oil Or Ash Encrusted If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of spark plugs. Ash encrusted spark plugs can be cleaned and reused. Premature Electrode Wear - Preignition Damage PREIGNITION DAMAGE Preignition Damage Excessive combustion chamber temperature can cause preignition damage. First, the center electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Other possible causes include ignition timing over-advanced and incorrect spark plug heat range. Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 980 center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Determine if the spark plugs are the correct type, as specified on the VECI label, or if other operating conditions are causing engine overheating. Red, Brown, Yellow or White Deposits - Fuel Additives SCAVENGER DEPOSITS Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed using standard procedures. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and reused. Shiny Yellow Glaze COMBUSTION DEPOSITS A shiny yellow glaze coating on the spark plug insulator is evidence of metallic by-products of fuel combustion, caused by chemical additives in certain fuels. Avoid sudden acceleration with wide open throttle after long periods of low speed driving. Spark plugs with combustion deposits can be cleaned and reused. Spark Plug Inspection - Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance Schedules. - Spark plugs that have low mileage may be cleaned and reused if not otherwise defective -- SEE Spark Plug Condition. After cleaning, file the center electrode flat with a small point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The spark plug gap is 0.033 to0.038 in. - Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Wet Oily Deposits FUEL FOULING A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air and reinstall them in the engine. White or Gray - Burned or Blistered Insulator SPARK PLUG OVERHEATING Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 981 Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in. per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug overheating. Also check for lean air-fuel mixture. Check the torque value of the plugs to ensure good plug-engine seat contact. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 982 Spark Plug: Adjustments Setting Spark Plug Electrode Gap Fig.2 Setting Spark Plug Electrode Gap Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground -- center electrode. Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap .............................................................................................................................................. ............................................. 0.033 to 0.038 in Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 983 Spark Plug: Service and Repair CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. CAUTION: Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion. SPARK PLUG REMOVAL 1. Remove the spark plug using a quality socket with a rubber or foam insert. 2. Inspect the spark plug condition. SPARK PLUG CLEANING Spark plugs that have low mileage may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. SPARK PLUG INSTALLATION 1. To avoid cross threading, start the spark plug into the cylinder head by hand. 2. Tighten spark plugs to 28 Nm (20 ft lb) torque. 3. Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube. 4. Connect coil. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications COMPRESSION PRESSURE (at 250 - 400 RPM): Standard .............................................................................................................................................. ............................ 1172 - 1551 kPa (170 - 225 psi) Minimum ............................................................. ................................................................................................................................... 689 kPa (100 psi) COMPRESSION PRESSURE DIFFERENCE OF ALL CYLINDER: Maximum ............................................................................................................................................. ....................................................................... 25% VACUUM: Manifold ............................................................................................................................................... .......................................... 60 kPa (18 inches Hg) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 987 Compression Check: Testing and Inspection PROCEDURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire (Conventional Ignition System). For Direct Ignition System (DIS) disconnect the coil connector. 5 . Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adaptor into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is reached on gage. Record this pressure as #1 cylinder pressure. 7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 9. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. 11. Clean or replace spark plugs as necessary and adjust gap. Tighten to specifications. 12. Test resistance of spark plug cables. Perform secondary circuit inspection. 13. Test coil output voltage, primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at idle and different RPM ranges. 15. The air filter elements should be replaced as specified. 16. Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt drives. 18. Road test vehicle as a final test. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates this engine is equipped with hydraulic lifters or lash adjusters and therefore does not require adjustment. See "Rocker Arm: Service and Repair" for further information. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications Timing Belt: Specifications Timing Belt Service Replacement Interval Information Not Supplied by the Manufacturer. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation Timing Belt: Service and Repair Timing Belt Removal and Installation CAUTION: Camshaft or crankshaft should not be rotate after timing belt is removed. Damage to valve components may occur. Always align timing marks before removing timing belt. REMOVAL 1. Remove crankshaft damper bolt. 2. Remove engine mount bracket and timing belt cover fasteners, remove cover. 3. Align camshaft timing marks. Loosen timing belt tensioner fasteners and remove timing belt. CAUTION: Do not loosen, tighten, or remove the tensioner pivot bolt. INSTALLATION 1. When tensioner is removed from the engine it is necessary to compress the plunger into the tensioner body. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 996 2. Place the tensioner into a vise and slowly compress the plunger. CAUTION: Index the tensioner in the vise the same way it is installed on the engine. This is to ensure proper pin orientation when tensioner is installed on the engine. 3. When plunger is compressed into the tensioner body install a pin through the body and plunger to retain plunger in place until tensioner is installed. 4. Set crankshaft sprocket to Top Dead Center (TDC) by aligning the sprocket with the arrow on the oil pump housing, then back off to 3 notches before TDC. 5. Set camshafts timing marks together by aligning notches on sprockets. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 997 6. Rotate crankshaft 1/2 tooth counterclockwise from TDC. 7. Install timing belt in this direction. Starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprockets and then around the tensioner pulley. 8. Move crankshaft sprocket to TDC to take up belt slack. Install tensioner to Clock but do not tighten fasteners. 9. Using a torque wrench on the tensioner pulley apply 28 Nm (250 inch lbs.) of torque to tensioner. 10. With torque being applied to the tensioner pulley move the tensioner up against the tensioner pulley bracket and tighten fasteners to 31 Nm (275 inch lbs.). 11. Pull tensioner plunger pin. Pretension is correct when pin can be removed and installed freely. 12. Rotate crankshaft 2 revolutions and check the alignment of the timing marks. 13. Install front half of timing cover. 14. Install engine mount bracket. 15. Install right engine mount. 16. Remove jack from under engine. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 998 17. Install crankshaft damper using M12 1.75 x 150 mm bolt, washer, thrust bearing and nut from Special Tool 6792. Install crankshaft damper bolt and tighten to 142 Nm (105 ft. lbs.). 18. Install accessory drive belts. 19. Raise vehicle on hoist and install right inner splash shield. 20. After timing belt has been replaced, use a Diagnostic Readout Box (DRB), or equivalent select adjustments and then relearn CMP/CKP, to relearn camshaft and crankshaft timing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 999 Timing Belt: Service and Repair Camshaft and Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1000 Timing Belt: Service and Repair Camshaft Sprockets and Timing Procedure With Cover Installed 1. Remove number one spark plug. 2. Using a dial indicator, set number one cylinder to Top Dead Center (TDC) on the compression stroke. 3. Remove the timing belt access cover from the engine. 4. Check the timing marks on the camshaft sprockets, they should align with each other. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist Drive Belt: Customer Interest Drive Belt - Momentary Loss of Power Steering Assist NO: 07-04-97 GROUP: Accessory Belt DATE: Jun. 6, 1997 SUBJECT: Momentary Loss Of Power Steering Assist When Driving Through Heavy Rain - Deep Puddles MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Momentary loss of power steering assist when driving through heavy rain and/or deep puddles. Loss of power steering is caused by water intrusion into the accessory drive belt area. DIAGNOSIS: Inspect the belt for glazing and/or cracks, if either is found replace the belt following the repair procedure found in the 1997 Neon Service Manual (Publication No. 81-270-7025) Page 7-21. Determine the road conditions the driver of the vehicle was encountering at the time the loss of power assist was experienced. If the driver indicates the loss of power steering assist was during times of heavy rain or deep puddles, perform the Repair Procedure. PARTS REQUIRED: AR(1) 04612247 Belt, Accessory Drive - Power steering and A/C Compressor REPAIR PROCEDURE: This bulletin involves correcting the tension on the power steering accessory drive belt. 1. Loosen the power steering pump locking bolts A and B and pivot bolt C (Illustration) to allow adjustment of belt tension. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist > Page 1009 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square hole "D" on the power steering pivot bracket. Adjust the tension as follows: Belt tension with no belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 100 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). Belt tension with belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 135 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). C. Start the engine and allow the vehicle to idle for 15 minutes to allow the belt to seat. D. Repeat the belt tensioning procedure, set belt tension to 135 lb. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-11-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist Drive Belt: All Technical Service Bulletins Drive Belt - Momentary Loss of Power Steering Assist NO: 07-04-97 GROUP: Accessory Belt DATE: Jun. 6, 1997 SUBJECT: Momentary Loss Of Power Steering Assist When Driving Through Heavy Rain - Deep Puddles MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Momentary loss of power steering assist when driving through heavy rain and/or deep puddles. Loss of power steering is caused by water intrusion into the accessory drive belt area. DIAGNOSIS: Inspect the belt for glazing and/or cracks, if either is found replace the belt following the repair procedure found in the 1997 Neon Service Manual (Publication No. 81-270-7025) Page 7-21. Determine the road conditions the driver of the vehicle was encountering at the time the loss of power assist was experienced. If the driver indicates the loss of power steering assist was during times of heavy rain or deep puddles, perform the Repair Procedure. PARTS REQUIRED: AR(1) 04612247 Belt, Accessory Drive - Power steering and A/C Compressor REPAIR PROCEDURE: This bulletin involves correcting the tension on the power steering accessory drive belt. 1. Loosen the power steering pump locking bolts A and B and pivot bolt C (Illustration) to allow adjustment of belt tension. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist > Page 1015 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square hole "D" on the power steering pivot bracket. Adjust the tension as follows: Belt tension with no belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 100 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). Belt tension with belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 135 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). C. Start the engine and allow the vehicle to idle for 15 minutes to allow the belt to seat. D. Repeat the belt tensioning procedure, set belt tension to 135 lb. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-11-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1016 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1017 Drive Belt: Description and Operation If the engine is equipped with power steering or air conditioning, it will have 2 drive belts. One belt drives the generator, the other drives the Power Steering and Air Conditioning. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1018 Drive Belt: Testing and Inspection Belt replacement under any or all of the following conditions is required, excessive wear, frayed cords or severe glazing. Poly-V-Belt system with back drive pulley may develop minor cracks across the ribbed side (due to reverse bending). These minor cracks are considered normal and acceptable. Cracks parallel are not. NOTE: Do not use any type of belt dressing or restorer on Poly-V-Belt and V-Belt Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Adjustments > A/C Belt Adjustment Drive Belt: Adjustments A/C Belt Adjustment PROPER BELT TENSION Satisfactory performance of the belt driven accessories depends on belt condition and proper belt tension. Refer to Accessory Drive Belt Inspection in this section. There are two belt tensioning methods given in order of preference: Belt tension gauge method. - Torque equivalent method. NOTE: The belt tension gauge method usually requires the vehicle to be raised on a hoist and the splash shield removed. TORQUE EQUIVALENT METHOD Adjustable accessory brackets provided with a 13 mm (1/2 inch) square hole for a torque wrench can use an equivalent torque value for belt adjustment. Equivalent torque values for adjusting these accessory drive belts are specified in above image. BELT TENSION GAUGE METHOD Use belt tensioning Special Tool Kit C-4162 for conventional belts and Poly-V-belts. Adjust the belt tension for a New or Used belt as prescribed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Adjustments > A/C Belt Adjustment > Page 1021 Drive Belt: Adjustments Alternator Belt Adjustment PROPER BELT TENSION Satisfactory performance of the belt driven accessories depends on belt condition and proper belt tension. Refer to Accessory Drive Belt Inspection in this section. There are two belt tensioning methods given in order of preference: Belt tension gauge method. - Torque equivalent method. NOTE: The belt tension gauge method usually requires the vehicle to be raised on a hoist and the splash shield removed. TORQUE EQUIVALENT METHOD Adjustable accessory brackets provided with a 13 mm (1/2 inch) square hole for a torque wrench can use an equivalent torque value for belt adjustment. Equivalent torque values for adjusting these accessory drive belts are specified in above image. BELT TENSION GAUGE METHOD Use belt tensioning Special Tool Kit C-4162 for conventional belts and Poly-V-belts. Adjust the belt tension for a New or Used belt as prescribed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Adjustments > A/C Belt Adjustment > Page 1022 Drive Belt: Adjustments Power Steering Pump Belt Adjustment PROPER BELT TENSION Satisfactory performance of the belt driven accessories depends on belt condition and proper belt tension. Refer to Accessory Drive Belt Inspection in this section. There are two belt tensioning methods given in order of preference: Belt tension gauge method. - Torque equivalent method. NOTE: The belt tension gauge method usually requires the vehicle to be raised on a hoist and the splash shield removed. TORQUE EQUIVALENT METHOD Adjustable accessory brackets provided with a 13 mm (1/2 inch) square hole for a torque wrench can use an equivalent torque value for belt adjustment. Equivalent torque values for adjusting these accessory drive belts are specified in above image. BELT TENSION GAUGE METHOD Use belt tensioning Special Tool Kit C-4162 for conventional belts and Poly-V-belts. Adjust the belt tension for a New or Used belt as prescribed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Belt Drive Belt: Service and Repair A/C Belt 1. Loosen the power steering pump locking bolts A and B and pivot bolt C to remove and install belt and/or adjust belt tension. 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square D hole on the power steering pivot bracket. Adjust tension to specification. 3. Tighten in order, first tighten locking bolt A to 27 Nm (20 ft. lbs.) then, bolt B to 27 Nm (20 ft. lbs.) Then pivot bolt C to 54 Nm (40 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Belt > Page 1025 Drive Belt: Service and Repair Alternator Belt 1. Loosen pivot bolt E then locking nut F and adjusting bolt G to remove and install belt and/or adjust belt tension. 2. Tighten adjusting bolt G. Adjust belt tension to specification. 3. Tighten pivot bolt E to 54 Nm (40 ft. lbs.). Locking nut F to 54 Nm (40 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Belt > Page 1026 Drive Belt: Service and Repair Power Steering Belt 1. Loosen the power steering pump locking bolts A and B and pivot bolt C to remove and install belt and/or adjust belt tension. 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square D hole on the power steering pivot bracket. Adjust tension to specification. 3. Tighten in order, first tighten locking bolt A to 27 Nm (20 ft. lbs.) then, bolt B to 27 Nm (20 ft. lbs.) Then pivot bolt C to 54 Nm (40 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Page 1027 Belt Tension Gauge C-4162 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Fig. 104 Air Intake Duct Fig. 105 Removal/Installation of Air Inlet Duct NOTE: Neon vehicles do not use a heated air inlet system. The PCM adjusts fuel injector pulse width and ignition timing to compensate for different ambient temperatures. NOTE: The air cleaner attaches to a bracket on the rear of the cylinder head. An ambient air duct supplies underhood air for the engine. REMOVAL 1. Remove air intake tube (Fig. 104) from air cleaner and intake manifold (Fig. 105). Fig. 106 Removal/Installation Air Cleaner Front Housing and Element 2. Tighten clasps on top of air cleaner housing. Rotate front of housing forward then lift front away from air cleaner housing (Fig 106). 3. Remove air cleaner element from front housing (Fig. 106). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1033 INSTALLATION 1. Install air cleaner element into front housing. 2. Rotate front of housing forward then lower into place and locate tabs in slots. - Fasten clasps on top of air cleaner housing. - Install air intake duct at air cleaner and intake manifold. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications Fluid Filter - A/T: Specifications Mounting Screw ................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1041 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 12 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) 6. Replace Pressure test port cap when finished releasing pressure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications To Adapter ........................................................................................................................................... ..................................................... 20 Nm (15 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 1045 Oil Filter: Description and Operation All engines are equipped with a high quality full flow, disposable type oil filter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 1046 Oil Filter: Service and Repair CAUTION: When servicing the oil filter avoid deforming the filter, install tool band strap against the seam at the base of the filter. The seam, joining the can to the base is reinforced by the base plate. 1. Turn counter clockwise to remove. 2. To install, lubricate new filter gasket. Check filter mounting surface. The surface must be smooth, flat and free of debris or old pieces of rubber. Screw filter on until gasket contacts base. Tighten to 21 Nm (15 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Water Pump Inlet Tube <--> [Coolant Line/Hose] > Component Information > Service and Repair Water Pump Inlet Tube: Service and Repair The inlet tube connects the water pump to the radiator and heater core. This tube is sealed by an O-ring and held in place by fasteners to the block. REMOVAL CAUTION: Do not use any sharp tools to remove hoses from inlet tube. This may cause the tube to leak. 1. Drain cooling system. 2. Remove upper radiator hose to access the hose connections at the inlet tube. Figure 19 3. Remove lower radiator hose and heater hose from the inlet tube. 4. Remove the two fasteners that hold the inlet tube to the block and one fastener that holds the intake manifold to inlet tube. Figure 20 5. Rotate tube while removing the tube from the engine block. INSTALLATION 1. Inspect the O-ring for damage before installing the tube into the cylinder block. Replace O-ring as necessary. 2. Lubricate O-ring with coolant and install inlet tube into the cylinder block opening. 3. Install two fasteners to the engine block and the one fastener to the intake manifold. Tighten fasteners to 12 Nm (105 inch lbs.). 4. Connect lower radiator hose and heater hose to inlet tube. 5. Install upper radiator hose. 6. Fill cooling system. 7. Pressure system to 104 kPa (15 psi) to check for leaks. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair Heater Hose: Service and Repair CAUTION: When removing hoses from heater core inlet or outlet nipples DO NOT exert excess pressure. The heater core may become damaged and leak engine coolant. NOTE: Review Cooling System Precautions before proceeding with this operation. REMOVAL 1. Drain engine cooling system. 2. Remove clamp at end of heater hose to be removed. Heater Hose Quick Connect 3. ON Right Hand Drive (RHD) vehicles, heater hoses at the heater core connection have quick connects. The quick connect consist of two pieces; a quick connect and insert. The quick connect is removed by compressing the insert with a pliers, and pulling the quick connect free of the insert/nipple. Carefully compressed insert pulling the quick connect from connector nipple. The insert will remain on the connector nipple as the quick connect is removed. 4. Remove the heater hose clamp from the heater hose at the block and remove hose. INSTALLATION NOTE: The insert should be removed from the connector nipple and placed inside of the quick connect before reassembly. For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation Hose/Line HVAC: Description and Operation DISCHARGE LINE Discharge Line The discharge line is the line that goes from the compressor to the condenser. It has no serviceable parts except the rubber 0-rings. If the line is found to be leaking or is damaged it must be replaced as an assembly. LIQUID LINE Liquid/Suction Line The liquid line is the line that goes from the condenser to the drier. It has no serviceable parts except the rubber 0-rings. If the line is found to be leaking or is damaged it must be replaced as an assembly. SUCTION LINE The suction line is the large line that connects to the expansion valve and goes to the compressor. It also has a small line that goes to the filter/ drier. The suction line uses a gasket on the expansion valve side and rubber 0-rings on all other connections. There are no serviceable parts on the suction line other than the rubber 0-rings and expansion valve gasket. If the line is found to be leaking or is damaged it must be replaced as an assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Page 1057 Hose/Line HVAC: Service and Repair HANDLING TUBING AND FITTINGS Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and moisture can enter the system when it is opened for repair or replacement of lines or components. The refrigerant oil will absorb moisture readily out of the air. This moisture will convert to acids within a closed system. CAUTION: The system must be completely empty before opening any fitting or connection on the refrigerant system. Open fittings with caution even after system has been emptied. If pressure is noticed as a fitting is loosened, tighten fitting and evacuate system again. BENDING FLEX HOSE A good rule for the flexable hose lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharper bends will reduce the flow of the refrigerant. The flexible hose lines should be routed at least 3 inches away from exhaust manifolds. Inspect all flexible hose lines to make sure they are in good condition and properly routed. CAUTION: The use of correct wrenches when making connections is very important. Improper wrenches or the improper use of wrenches can damage the fittings. INTERNAL DAMAGE The internal parts of the A/C system will remain stable as long as moisture free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture, or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. OPENING SYSTEM When it is necessary to open the refrigeration system, have everything needed to service the system ready. The system should not be left open any longer than necessary. Cap or Plug all lines and fittings as soon as they are opened. This will prevent the entrance of dirt and moisture into the system. All new lines and components should be capped or sealed until they are ready to be used. CAUTION: All tools, including the refrigerant dispensing manifold, the manifold gauge set, and test hoses should be kept dry. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Pressure and Return Line Tube Nuts ................................................................................................................................................... 31 Nm (275 inch lbs.) Pressure Hose Banjo Bolt ..................................................................................... .................................................................................... 34 Nm (25 ft. lbs.) Routing Bracket ................ .............................................................................................................................................................. .......... 23 Nm (17 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump Power Steering Line/Hose: Service and Repair Supply Hose From Reservoir to Pump WARNING: Power steering oil, engine parts and exhaust system may be extremely hot if engine has been running. Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch hot exhaust manifold or catalyst. CAUTION: Care must be used when removing the power steering fluid supply hose from power steering fluid reservoir. If excessive force is used when trying to remove hose from nipple on power steering fluid reservoir, nipple can break off of the reservoir. REMOVE 1. Remove hose clamp, attaching power steering fluid supply hose to power steering fluid reservoir. Then remove power steering fluid supply hose from power steering fluid reservoir. 2. Remove hose clamp, attaching power steering fluid supply hose to the power steering pump. Then remove power steering fluid supply hose from power steering pump fitting. 3. Remove power steering fluid supply hose from engine. INSTALL 1. Install power steering fluid supply hose back on engine making sure it is correctly routed. CAUTION: Care must be used when installing power steering fluid supply hose on power steering fluid reservoir. If excessive force is used when trying to install hose on nipple of power steering fluid reservoir, nipple can be broken off the reservoir. 2. Install power steering fluid supply hose on power steering fluid reservoir fitting. Install hose clamp on power steering fluid supply hose at power steering fluid reservoir. Be sure hose clamp is installed on return hose past upset bead on power steering fluid reservoir. 3. Install power steering fluid supply hose on power steering pump fitting. Install hose clamp on power steering fluid supply hose at power steering pump fitting. Be sure hose clamp is installed on power steering fluid supply hose past upset bead on power steering pump fitting. 4. Start the engine and let run for a few seconds. Then turn the engine off. 5. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 6. Raise front wheels of vehicle off the ground. 7. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Then turn the engine off. 8. Add power steering fluid if necessary. 9. Lower the vehicle and turn the steering wheel slowly from lock to lock. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1063 10. Stop the engine. Check the fluid level and refill as required. 11. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. 12. After hose is installed, check for leaks at all hose connections. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1064 Power Steering Line/Hose: Service and Repair Power Steering Fluid Pressure Hose Removal CAUTION: Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent entry of foreign material into the components. WARNING: Power steering oil, engine parts and exhaust system may be extremely hot if engine has been running. Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch hot exhaust manifold or catalyst. 1. Raise vehicle. 2. Remove bolt attaching power steering hose routing bracket to front suspension crossmember. 3. Disconnect power steering pressure hose at power steering gear. Drain power steering fluid from power steering pump and hose through open end of hose. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1065 4. Remove power steering pressure hose from routing clip on generator shield. 5. Lower vehicle. 6. Remove bolt, attaching power steering pressure hose routing clip, to generator shield. 7. Loosen and remove Banjo bolt, and power steering pressure hose from pressure fitting on power steering pump. 8. Power steering fluid pressure hose is removed from the vehicle from the top of the engine compartment. 9. Discard all used O-rings located at ends of power steering pressure hose and Banjo bolt. Installation 1. Install power steering pressure hose in vehicle from top of engine compartment. 2. Using a lint free towel, wipe clean all open power steering hose ends, and the power steering pump and steering gear ports. 3. Install new O-ring on end of power steering pressure hose banjo fitting. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1066 4. Install a new O-ring on power steering pressure hose banjo fitting bolt. 5. Lubricate both O-rings using fresh clean power steering fluid. 6. Install banjo bolt into the power steering pressure hose banjo fitting. 7. Attach power steering pressure hose to outlet fitting on power steering pump. Do not tighten or torque pressure fitting Banjo bolt at this time. 8. Correctly route power steering pressure hose avoiding tight bends or kinking of the hose. Install power steering pressure hose to generator shield routing clip attaching screw but do not tighten at this time. 9. Raise vehicle. CAUTION: Hoses must remain away from exhaust system, vehicle components and unfriendly surfaces causing possible damage to power steering hoses. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1067 10. Route power steering pressure hose to pressure port on power steering gear. Install power steering pressure hose, on steering gear and loosely install tube nut into steering gear. Tighten and torque tube nut after routing bracket is installed, correctly positioning hoses in vehicle. 11. Install the power steering pressure and return hose routing clip on hoses. Install bolt attaching routing clip to front suspension crossmember. Torque routing clip to front suspension crossmember attaching bolt to 23 Nm (17 ft. lbs.). 12. Torque power steering pressure hose to steering gear tube nut to 34 Nm (25 ft. lbs.). 13. Install power steering pressure hose in routing clip on generator shield. 14. Lower Vehicle. 15. Position locating pin on power steering pressure hose banjo fitting so it is against power steering pump mounting bracket. While holding locating pin against power steering pump bracket, torque pump end Banjo bolt to 34 Nm (25 ft. lbs.). 16. Securely tighten bolt attaching power steering pressure hose bracket to generator shield. 17. Start the engine and let run for a few seconds. Then turn the engine off. 18. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 19. Raise front wheels of vehicle off the ground. 20. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Then turn the engine off. 21. Add power steering fluid if necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1068 22. Lower the vehicle and turn the steering wheel slowly from lock to lock. 23. Stop the engine. Check the fluid level and refill as required. 24. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. 25. After hose is installed, check for leaks at all hose connections. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1069 Power Steering Line/Hose: Service and Repair Power Steering Fluid Return Hose CAUTION: Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent entry of foreign material into the components. WARNING: Power steering oil, engine parts and exhaust system may be extremely hot if engine has been running. Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch hot exhaust manifold or catalyst. REMOVE 1. Raise vehicle. 2. Remove hose clamp, attaching return hose to steel tube at power steering gear. Let power steering fluid, drain from return hose and power steering fluid reservoir, until reservoir is empty. 3. Remove power steering return hose from routing clip on generator shield. 4. Lower vehicle. 5. Remove tube clip at generator shield attaching power steering fluid return hose to power steering fluid pressure hose. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1070 CAUTION: Care must be used when removing power steering fluid return hose from power steering fluid reservoir. If excessive force is used when trying to remove hose from nipple on power steering fluid reservoir, nipple can break off of the reservoir. 6. Remove hose clamp, attaching power steering return hose to power steering fluid reservoir. Then remove power steering return hose from power steering fluid reservoir 7. Remove the power steering return hose from the vehicle. The power steering return hose is removed from the top of the engine compartment. INSTALL 1. Install power steering return hose on vehicle. Power steering return hose is installed from the top of the vehicles engine compartment. CAUTION: Care must be used when installing power steering fluid return hose on power steering fluid reservoir. If excessive force is used when trying to install hose on nipple of power steering fluid reservoir, nipple can be broken off the reservoir. 2. Install power steering return hose on power steering fluid reservoir fitting. Install hose clamp on power steering return hose at power steering fluid reservoir. Be sure hose clamp is installed on return hose past upset bead on power steering fluid reservoir. 3. Raise vehicle. 4. Clip power steering return hose and pressure hose together. 5. Install power steering return hose on steel tube at power steering gear. Install hose clamp on power steering return hose at power steering gear. Be sure hose clamp is installed on return hose past upset bead on steel tube at power gear. 6. Install power steering return hose on routing clip at generator shield. 7. Lower vehicle. 8. Start the engine and let run for a few seconds. Then turn the engine off. 9. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 10. Raise front wheels of vehicle off the ground. 11. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Then turn the engine off. 12. Add power steering fluid if necessary. 13. Lower the vehicle and turn the steering wheel slowly from lock to lock. 14. Stop the engine. Check the fluid level and refill as required. 15. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. 16. After hose is installed, check for leaks at all hose connections. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Description and Operation Radiator Hose: Description and Operation WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE WORKING ON VEHICLE. RELIEVE PRESSURE BY PLACING A SHOP TOWEL OVER THE CAP AND WITHOUT PUSHING DOWN ROTATE IT COUNTER-CLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE AND WHEN THE SYSTEM STOPS PUSHING OUT COOLANT AND STEAM AND THE PRESSURE DROPS CONTINUE SERVICE. CAUTION: - Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clamp. Always wear safety glasses when servicing constant tension clamps. - A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only a original equipment clamp with matching number or letter. HOSES Radiator hoses should be routed without any kinks and indexed as designed. The use of molded hoses is recommended. A hardened, cracked, swollen or restricted hose should be replaced. Do not damage radiator inlet and outlet when loosening hoses. CLAMPS Spring type hose clamps are used in all applications. If replacement is necessary replace with the original Mopar equipment spring type clamp. The hose clamps are removed by using Special Tool 6094, or equivalent constant tension clamp pliers to compress hose clamp. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1078 Brake Fluid: Service Precautions CAUTION: Use only Mopar brake fluid or an equivalent from a tightly sealed container. Brake fluid must conform to DOT 3 specifications. Do not use petroleum-based fluid because seal damage in the brake system will result. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1079 Brake Fluid: Testing and Inspection CAUTION: The hydraulic fluid used in automotive brake systems is hygroscopic. This means that the hydraulic fluid tends to absorb moisture from the atmosphere over periods of time. As hydraulic brake fluid absorbs moisture, it effects the function of the vehicles hydraulic brake system. For this reason, the vehicle's hydraulic brake fluid should be drained and replaced using fresh clean hydraulic brake fluid every two years. When replacing hydraulic brake fluid, use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications. BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber parts or components containing rubber coming into contact with the brake fluid. This includes the master cylinder, proportioning valves, caliper seals, wheel cylinder seals, ABS hydraulic control unit (HCU), and all hydraulic fluid hoses. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1080 Brake Fluid: Service and Repair Master Cylinder Fluid Level CAUTION:Use only Mopar brake fluid or an equivalent from a tightly sealed container. Brake fluid must conform to DOT 3 specifications. Do not use petroleum-based fluid because seal damage in the brake system will result. Check master cylinder reservoir brake fluid level a minimum of twice a year. Master cylinder reservoirs are marked with the words FULL AND MIN indicating proper range of the master cylinder fluid level. If necessary, add specified brake fluid bringing level to the FULL mark on the side of the master cylinder brake fluid reservoir. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications Clutch Fluid Type ..................................................................................................................................................... ................................................ DOT3 Brake Fluid Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations Coolant: Technical Service Bulletins Engine - Coolant Recommendations NO: 07-03-97 GROUP: Cooling DATE: May 9, 1997 SUBJECT: Engine Coolant Usage THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-05-93 DATED NOV. 26, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1993 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-94000). THE COMPLETE BULLETIN IS REVISED. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1997 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger/ Power Ram/Power Ram Cab & Chassis 1989 - 1993 (AG) Daytona 1989 (AH) Lancer/LeBaron GTS 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1997 (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1997 (BR) Ram Truck 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1989 - 1992 (MJ) Comanche 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1997 (PR) Prowler 1992 - 1997 (SR) Viper/Viper Coupe 1997 (TJ) Wrangler 1989 - 1997 (XJ) Cherokee 1989 - 1995 (YJ) Wrangler 1993 - 1997 (ZJ) Grand Cherokee DISCUSSION: Some owners have expressed interest in using engine coolants made with propylene glycol instead of ethylene glycol due to its lower toxicity and resultant reduced hazards to children and animals. Based on recent test data, most owners should not experience significant effects on cooling system performance when using propylene glycol based coolant. The use of national brand propylene glycol based engine coolant that meets the same Chrysler ethylene glycol specification of MS-7170 (or equivalent ASTM D5216) is acceptable for Chrysler built vehicles. NOTE: ANTIFREEZE SOLD FOR PROTECTING PLUMBING ETC. (RV ANTIFREEZE) IS NOT A SUITABLE ENGINE COOLANT. However, owners should be discouraged from changing their engine coolant prior to the regularly scheduled maintenance period. Prematurely changing engine coolant unnecessarily adds to the risk of environmental exposure. Sufficient freeze protection for the region should be maintained. However, do not use more than a 55% solution (-35 F, -37 C). Use the chart that accompanies the propylene glycol coolant, since a higher concentration is required to obtain the same freeze points as ethylene glycol coolant. If the temperatures for your region fall below this, use ethylene glycol coolant. Under severe driving conditions (towing a trailer in hot weather etc.) there may be a slight loss in cooling performance. If this is noticed, the system should be changed back to ethylene glycol coolant. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations > Page 1088 The two types of coolant should not be mixed. The standard testers for measuring freeze protection will not provide an accurate reading when this occurs. If the cooling system is changed to propylene glycol, all the ethylene glycol coolant should be removed using an approved cooling system flush procedure. The freeze protection of propylene glycol cannot be measured with a standard cooling system hydrometer. A refractometer or hydrometer calibrated for propylene glycol is the preferred test tool. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System Capacity .................................................................................................................... ............................................................. 7.0L (7.4 qts) NOTE: Capacity includes heater and coolant reserve system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1091 Coolant: Fluid Type Specifications GENERAL INFORMATION Performance is measurable. For heat transfer pure water absorbs 1 btu for each degree of temperature rise for each pound of water. This formula is altered when necessary additives to control boiling, freezing, and corrosion are added as follows: Pure Water (1 btu) boils at 100°C (212°F) and freezes at 0°C (32°F). - 100 Percent ethylene glycol (0.7 btu) can cause an engine to run hot, cause detonation, and will freeze at -22°C (-8°F). - 50/50 Ethylene Glycol and Distilled Water (0.82 btu) is the recommended combination that provides a freeze point of -37°C (-35°F). The radiator, water pump, engine water jacket, radiator pressure cap, thermostat, temperature gauge, coolant sensor and heater are all designed for 50/50 ethylene glycol. - Where required, a 56 percent glycol and 44 percent water mixture will provide a freeze point of -46°C ( -50°F ). NOTE: Richer mixtures cannot be measured with field equipment and can lead to problems associated with 100 percent glycol. If there is doubt that the coolant mixture is to rich for field equipment to measure, put a sample in a clean container. Add exactly the same amount of water and retest. If the coolant in the vehicle is 100% antifreeze, the diluted sample will read 50%. If the coolant in the vehicle was 70% antifreeze and 30% water, the diluted sample will read as 35%, etc. SELECTION AND ADDITIVES The use of aluminum cylinder heads, intake manifolds, and water pumps requires special corrosion protection. Mopar Antifreeze or their equivalent are recommended for best engine cooling without corrosion. When mixed only to a freeze point of -37°C (-35°F) to -59°C (-50°F). If it looses color or becomes contaminated, drain, flush, and replace with fresh properly mixed solution. CAUTION: Do not use well water, or suspected water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > General Information Coolant: Description and Operation General Information GENERAL INFORMATION The cooling system is designed around the coolant. PICKING UP HEAT The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves. GIVING OFF HEAT Then carry this heat to the radiator where the tube/fin assemblies of these components can give off the heat to the air. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > General Information > Page 1094 Coolant: Description and Operation Coolant Performance GENERAL INFORMATION Performance is measurable. For heat transfer pure water absorbs 1 btu for each degree of temperature rise for each pound of water. This formula is altered when necessary additives to control boiling, freezing, and corrosion are added as follows: Pure Water (1 btu) boils at 100°C (212°F) and freezes at 0°C (32°F). - 100 Percent ethylene glycol (0.7 btu) can cause an engine to run hot, cause detonation, and will freeze at -22°C (-8°F). - 50/50 Ethylene Glycol and Distilled Water (0.82 btu) is the recommended combination that provides a freeze point of -37°C (-35°F). The radiator, water pump, engine water jacket, radiator pressure cap, thermostat, temperature gauge, coolant sensor and heater are all designed for 50/50 ethylene glycol. - Where required, a 56 percent glycol and 44 percent water mixture will provide a freeze point of -46°C ( -50°F ). NOTE: Richer mixtures cannot be measured with field equipment and can lead to problems associated with 100 percent glycol. If there is doubt that the coolant mixture is to rich for field equipment to measure, put a sample in a clean container. Add exactly the same amount of water and retest. If the coolant in the vehicle is 100% antifreeze, the diluted sample will read 50%. If the coolant in the vehicle was 70% antifreeze and 30% water, the diluted sample will read as 35%, etc. SELECTION AND ADDITIVES The use of aluminum cylinder heads, intake manifolds, and water pumps requires special corrosion protection. Mopar Antifreeze or their equivalent are recommended for best engine cooling without corrosion. When mixed only to a freeze point of -37°C (-35°F) to -59°C (-50°F). If it looses color or becomes contaminated, drain, flush, and replace with fresh properly mixed solution. CAUTION: Do not use well water, or suspected water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Page 1095 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1100 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1101 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1102 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1103 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1104 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Service Fill ........................................................................................................................................... ............................................................. 3.7L (4.0 Qt) Overhaul with torque converter empty .............................................................................................................................................................. 8.1L (8.6 Qt) Overhaul with torque converter empty (fleet vehicles) ..................................................................................................................................... 8.7L (9.2 Qt) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1107 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ............................................................................................................ ....................................................... MOPAR ATF +4 Type 9602 or Equivalent Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid .............................................................................................................................. ............................................. 1.9-2.2L (4.0-4.6 Pints) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1112 Fluid - M/T: Fluid Type Specifications Transmission Fluid MOPAR type M.S. 9417 Manual Transaxle Fluid Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 4.2L (4.5 Qt) Capacity shown is without filter. When replacing filter, additional oil may be needed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1117 Engine Oil: Fluid Type Specifications Engine Oil API Classification .............................................................................................................................................................. SJ ECII or SJ/CD ECII or Above Above -10°F (-23°C)......................................................................... .......................................................................................................................... 10W-30 Below 100°F (38°C)................................................................................................................................................... .................................................. 5W-30 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1118 Engine Oil: Service Precautions CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1119 Engine Oil: Description and Operation CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result. API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certified or an oil that conforms to the API Service Grade SH or SH/CD. SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. SAE 30 specifies a single viscosity engine oil. Engine oils also have multiple viscosities. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation. ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. They are designated as either ENERGY CONSERVING or ENERGY CONSERVING II. CONTAINER IDENTIFICATION Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans. ENGINE OIL ADDITIVES In some instances, such as infrequent operation, short trip driving, and during break-in after a major overhaul, addition of special materials containing anti-rust and anti-scuff additives are beneficial. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1120 Engine Oil: Testing and Inspection The best time to check engine oil level is after it has sat overnight, or if the engine has been running, allow the engine to be shut off for at least 5 minutes before checking oil level. NOTE: Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Add only when the level is at or below the ADD mark. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1121 Engine Oil: Service and Repair CHANGING ENGINE OIL Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. Refer. to Hoisting and Jacking Recommendations. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 6. Install drain plug in crankcase. 7. Lower vehicle and fill crankcase with specified type and amount of engine oil. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Fluid: Customer Interest Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 1130 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1136 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1137 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1138 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Fluid: All Technical Service Bulletins Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 1143 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1149 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1150 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1151 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1152 Power Steering Fluid: Specifications WARNING: Fluid level should be checked with engine off to prevent injury from moving parts. Do not use automatic transmission fluid in the power steering system. Do not overfill the power steering system. Wipe reservoir filler cap free of dirt. Then check fluid level. The dipstick should indicate COLD when fluid is at normal ambient temperature, approximately 21°C - 27°C (70°F - 80°F). In all pumps add fluid as necessary, use only Mopar (R) Power Steering Fluid, or equivalent. DO NOT USE ANY TYPE OF AUTOMATIC TRANSMISSION FLUID. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1153 Power Steering Fluid: Service and Repair WARNING: Fluid level should be checked with engine off to prevent injury from moving parts. Do not use automatic transmission fluid in the power steering system. Do not overfill the power steering system. Wipe reservoir filler cap free of dirt. Then check fluid level. The dipstick should indicate COLD when fluid is at normal ambient temperature, approximately 21°C - 27°C (70°F - 80°F). In all pumps add fluid as necessary, use only Mopar (R) Power Steering Fluid, or equivalent. DO NOT USE ANY TYPE OF AUTOMATIC TRANSMISSION FLUID. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R134a Capacity ................................................................................................................................... ........................................ 0.78 kg (28 oz. or 1.57 lbs) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1158 Refrigerant: Fluid Type Specifications Hydrofluorocarbon (HFC), ................................................................................................................... ............................................... R-134a liquefied gas Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Total System ........................................................................................................................................ ........................................................... 200 ml 6.75 oz. Condenser ........................................................................................................................................... ................................................................ 30 ml 1.0 oz. Evaporator ........................................................................................................................................... ............................................................... 59 ml 2.0 oz. Filter-Drier ...................................................... ................................................................................................................................................... 30 ml 1.0 oz. A/C Lines ............................................................................................................................................. .............................................................. 44 ml 1.5 oz. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1163 Refrigerant Oil: Fluid Type Specifications Synthetic-based, Polyalkylene Glycol .................................................................................................. .......................................................................... ND-8 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1164 Refrigerant Oil: Service and Repair It is important to have the correct amount of oil in the A/C system to ensure proper lubrication of the compressor. Too little oil will result in damage to the compressor. Too much oil will reduce the cooling capacity of the system and consequently result in higher discharge air temperatures. NOTE: The oil used in the compressor is ND8 PAG R-134a refrigerant oil. Only refrigerant oil of the same type should be used to service the system. Do not use any other oil. The oil container should be kept tightly capped until it is ready for use. Tightly cap afterwards to prevent contamination from dirt and moisture. Refrigerant oil will quickly absorb any moisture it comes in contact with. Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. It will not be necessary to check oil level in the compressor or to add oil unless there has been an oil loss. Oil loss at a leak point will be evident by the presence of a wet, shiny surface around the leak. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures GENERAL INFORMATION The base brake system must be bled anytime air is permitted to enter the hydraulic system, due to disconnection of brake lines, hoses or components. The Antilock Brake System (ABS), particularly the Hydraulic Control Unit (HCU), should only be bled when the HCU is. replaced or removed from the vehicle, or if there is reason to believe the HCU has ingested air. Under most circumstances that would require brake bleeding, only the base brake system needs to be bled. It is important to note that excessive air in the brake system will cause a soft or spongy feeling brake pedal. During Bleeding Operations - be sure that the brake fluid level remains close to the FULL level in the reservoir. Check the fluid level periodically during the bleeding procedure and add DOT 3 brake fluid as required. The Bendix ABX-4 Brake System must be bled as two independent braking systems. The non ABS portion of the brake system is to be bled the same as any non ABS system. Refer to Brakes Service and Repair for the proper bleeding procedure to be used. This brake system can be either pressure bled or manually bled. The ABS portion of brake system MUST be bled separately. This bleeding procedure requires the use of the DRB scan tool and the bleeding sequence procedure outlined below. ABS BLEEDING PROCEDURE When bleeding the ABS system, the following bleeding sequence MUST be followed to insure complete and adequate bleeding. The ABS system can be bled using a Manual bleeding procedure or standard Pressure Bleeding Equipment. If the brake system is to be bled using pressure bleeding equipment, refer to Brakes Service and Repair. 1. Assemble and install all brake system components on vehicle making sure all hydraulic fluid lines are installed and properly torqued. ABS System Diagnostic Connector 2. Connect the DRB scan tool to the diagnostics connector. The diagnostics connector is located under the steering column cover, directly below the steering column. 3. Using the DRB scan tool, check to make sure the CAB does not have any fault codes stored. If it does, remove them using the DRB scan tool. WARNING: WHEN BLEEDING THE BRAKE SYSTEM WEAR SAFETY GLASSES. A CLEAR BLEED TUBE MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A CLEAR CONTAINER FILLED PART WAY WITH CLEAN BRAKE FLUID. DIRECT THE FLOW OF BRAKE FLUID AWAY FROM THE PAINTED SURFACES OF THE VEHICLE. BRAKE FLUID AT HIGH PRESSURE MAY COME OUT OF THE BLEEDER SCREWS WHEN OPENED. 4. Bleed the base brake system using the standard pressure or manual bleeding procedure as outlined in Brakes Service and Repair. 5. Using the DRB scan tool, go to the "Bleed ABS" routine. Apply the brake pedal firmly and initiate the "Bleed ABS" cycle one time. Release the brake pedal. 6. Bleed the base brake system again, as in step Step 4 above. 7. Repeat steps Step 5 and Step 6 above until brake fluid flows clear and free of bubbles. Check brake fluid level in reservoir periodically to prevent reservoir from running low on brake fluid. 8. Test drive the vehicle to be sure brake are operating correctly and that pedal is solid. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 1169 Brake Bleeding: Service and Repair Pressure Bleeding (Preferred Procedure) Air Trapped In Brake System Method For Purging Air From Brake System Bleeder Screw CAUTION: - Before removing the Master Cylinder cover, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder. - Use bleeder tank Special Tool C-3496-B, or equivalent with required adapter for the master cylinder reservoir to pressurize the hydraulic system for bleeding. NOTE: - For bleeding the ABS hydraulic system, refer to Hydraulic Control Unit. - Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. PROCEDURE When bleeding the brake system, some air may be trapped in the brake lines or valves far upstream, as much as ten feet from the bleeder screw. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 1170 Therefore, it is essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out. The following wheel sequence for bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulic system. ^ Left rear wheel ^ Right front wheel ^ Right rear wheel ^ Left front wheel 1. Attach a clear plastic hose to the bleeder screw starting at the right rear wheel and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. 2. Open the bleeder screw at least one full turn or more to obtain an steady stream of brake fluid. 3. After 4 to 8 ounces of fluid has been bled through the brake and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 4. Repeat the procedure at all the other remaining bleeder screws. Then check the pedal for travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to monitor the fluid level in the pressure bleeder. It must stay at the proper level so air will not be allowed to reenter the brake system through the master cylinder reservoir. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components . Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 1175 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming 1. Verify that the negative battery cable is disconnected and isolated. 2. Connect scan tool (DRB) to Data Link connector, located at right side of the steering column and at the lower edge of the lower instrument panel. 3. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 4. After checking that no one is inside the vehicle, connect the battery negative terminal. 5. Using the scan tool, read and record active diagnostic code data. 6. Read and record any stored diagnostic codes. 7. Refer to the airbag system Diagnostic Test if any diagnostic codes are found in Step 5 or Step 6. 8. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the airbag system Diagnostic Test. If the airbag warning lamp either fails to light with the ignition switch ON, or the light goes on and stays on, there is a system malfunction. Refer to the airbag system Diagnostic Test. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations Fuse: Locations Fuse Locations Fuse Locations Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1184 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1185 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1186 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1187 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1188 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1189 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1190 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1191 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1192 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1193 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1194 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1195 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1196 Fuse Block: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1197 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1198 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1199 Fuse Block: Connector Views Fuse Block (Part 1 Of 2) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1200 Fuse Block (Part 2 Of 2) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1201 Fuse Block: Electrical Diagrams Fuse Block (Part 1 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1202 Fuse Block (Part 2 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1203 Fuse Block (Part 3 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1204 Fuse Block (Part 4 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1205 Fuse Block (Part 5 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1206 Fuse Block (Part 6 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1207 Fuse Block (Part 7 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1208 Fuse Block (Part 8 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1209 Fuse Block (Part 9 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1210 Fuse Block (Part 10 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1211 Fuse Block (Part 11 Of 11) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation CIRCUIT OPERATION The Service Engine Soon lamp illuminates when the ignition switch is in the ON position and prior to starting the vehicle. The lamp will turn off after the vehicle is started. If while the vehicle is running a problem is detected in the engine control system the lamp is illuminated. This is accomplished by the Powertrain Control Module (PCM) grounding the G3 circuit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation The temporary spare tire is designed for emergency use only. The original tire should be repaired and reinstalled at the first opportunity, or replaced with a new. Do not exceed speeds of 50 MPH when the temporary spare tire is in use on the vehicle. Refer to the Owner's Manual for complete details. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Tire & Wheel - Runout Wheels: Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1225 Wheels: Specifications Lug Nuts .............................................................................................................................................. ................................. 109 - 150 Nm (80 - 110 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1226 Wheels: Description and Operation Original equipment wheels are designed for proper operation at all loads up to the specified maximum vehicle capacity. All models use steel or cast aluminum drop center wheels. Every wheel has raised sections between the rim flanges and rim drop well called safety humps. Initial inflation of the tires forces the bead over these raised sections. In case of air loss the raised sections help hold the tire in position on the wheel until the vehicle can be brought to a safe stop. Cast aluminum wheels require special balance weights to fit on the thicker flange of the rim and special wheel clamps for the alignment equipment. The wheel studs and nuts are designed for specific wheel applications and must be replaced with equivalent parts. Do not use replacement parts of lesser quality or of a substitute design. All aluminum wheels use wheel nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Vehicles that are equipped with bolt-on wheel covers use large nose wheel nuts. The wheel nuts used on a vehicle equipped with bolt-on wheel covers are externally threaded so that the wheel covers can be attached to the wheel nuts. Before installing a wheel, remove any buildup of corrosion on the wheel mounting surface. WARNING: Installing wheels without good metal-to-metal contact could cause loosening of wheel lug nuts. This could adversely affect the safety and handling of your vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1227 Wheels: Testing and Inspection Wheels must be replaced if they: - Have excessive run out - Are bent or dented - Leak air - Have damaged wheel lug/ nut holes Wheel repairs employing hammering, heating, welding or repairing leaks are not allowed. Original equipment replacement wheels should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The physical dimensions (diameter, width, offset, pilot hole and bolt circle) of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. Replacement with used wheels is not recommended. The service history of the rim may have included severe treatment or very high mileage. The rim could fail without warning. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1228 Wheels: Service and Repair Lug Nut Tightening Sequence To install the wheel and tire assembly, first position it properly on the mounting surface using the hub pilot as a guide. Then progressively tighten the lug nuts in the proper sequence to half of the required torque. Finally tighten the lug nuts in the proper sequence to 109 - 150 Nm (80 - 110 ft. lbs.). Never use oil or grease on studs or nuts. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Front To Knuckle Retaining Nut .................................................................................................................... ................................................ 216 Nm (160 ft. lbs.) Rear Hub Nut ............................................................................................................................................... ................................................. 217 Nm (160 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 1233 Wheel Bearing: Fluid Type Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1234 Wheel Bearing: Service Precautions CAUTION: The hub/bearing retaining nut must be tightened to but must not exceed its required torque specification. The proper torque specification of the retaining nut is critical to the life of the hub bearing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front Wheel Bearing: Description and Operation Front The front wheel hub bearing used is a Unit 1 type cartridge bearing. The wheel bearing is serviced separately from the front steering knuckle and front hub assembly. Installation and retention of the front wheel bearing into the steering knuckle, is by means of an interference press fit using a retaining compound and a retaining snap ring. Installation of the front hub into the front wheel bearing, must be done after wheel bearing and retaining snap ring is installed in steering knuckle. The unit 1 wheel bearing is serviced only as a complete assembly less the wheel hub. If the front wheel bearing requires replacement, the hub must be removed from the original wheel bearing and transferred to the replacement bearing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front > Page 1237 Wheel Bearing: Description and Operation Rear All vehicles are equipped with permanently lubricated and sealed for life rear wheel bearings. There is no periodic lubrication or maintenance recommended for these units. However, if servicing of a rear wheel bearing is required, refer to procedures in Testing and Inspection and Service and Repair for the inspection and replacement of the rear wheel bearing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Wheel Bearing: Testing and Inspection Front NOTE: The hub bearing is designed for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the hub bearing. With the wheel, disc brake caliper. and brake rotor removed, rotate the wheel hub. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the hub bearing exhibits any of these conditions during diagnosis, the hub bearing will require replacement, the bearing is not serviceable. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weapage from the hub bearing is considered normal and should not require replacement of the hub bearing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 1240 Wheel Bearing: Testing and Inspection Rear The rear hub and bearing assembly is designed for the life of the vehicle and should require no maintenance. The following procedure may be used for evaluation of bearing condition. With wheel and brake drum removed, rotate flanged outer ring of hub. Excessive roughness, lateral play or resistance to rotation may indicate dirt intrusion or bearing failure. If the rear wheel bearings exhibit these conditions during inspection, the hub and bearing assembly should be replaced. Damaged bearing seals and resulting excessive grease loss may also require bearing replacement. Moderate grease loss from bearing is considered normal and should not require replacement of the hub and bearing assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Removal 1. Remove the steering knuckle, hub and the hub bearing as an assembly from the vehicle. See: Steering and Suspension/Steering/Front Steering Knuckle/Service and Repair NOTE: The removal and installation of the steering knuckle hub bearing is to ONLY be done with the steering knuckle removed from the vehicle. Removal of the hub bearing from the steering knuckle MUST be done using an arbor press and the following procedure. 2. Install Bearing Splitter, Special Tool P334, or equivalent on the steering knuckle and hub/bearing assembly as shown to support steering knuckle when pressing out hub. 3. Position steering knuckle and hub and bearing in an arbor press supported by Bearing Splitter, Special Tool P334 as shown. 4. Position Driver, Special Tool 6644-2, or equivalent on the small end of the hub to drive hub out of bearing. Using arbor press remove hub from bearing. The one bearing race will come out with hub when hub is removed from bearing. 5. Remove Bearing Splitter, Special Tool P334, or equivalent from the steering knuckle. CAUTION: Safety goggles and or face protection should always be worn when removing the snap ring retaining the hub/bearing in the steering knuckle. When the snap ring is removed from the steering knuckle it could fly out of the steering knuckle with great force possibly causing personal injury. 6. Using a screw driver, remove the snap ring retaining the hub bearing in the steering knuckle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1243 7. Place steering knuckle in an arbor press supported by press blocks as shown. Press blocks must not obstruct hub bearing bore in steering knuckle so bearing can be pressed out of knuckle. Place Bearing Driver, Special Tool MB-990799, or equivalent on outer race of hub bearing. Press hub bearing completely out of the steering knuckle. 8. Install Bearing Splitter, Special Tool P334, or equivalent on hub so it is between the flange of the hub and the bearing race remaining on the hub. Place hub, bearing race and the bearing splitter in an arbor press as shown. Place Driver, Special Tool 6644-2, or equivalent on end of hub. Press the hub out of the bearing race. Installation 1. Wipe bore of steering knuckle clean of any grease or dirt with a clean dry shop towel. CAUTIONS: Do not use any type of solvent on the hub bearing when cleaning it. - The hub bearing must be wiped as clean as possible. Any remaining rust preventative on the bearing can effect the bonding action of the adhesive to the bearing. 2. Clean the rust preventative from the replacement hub bearing using a clean dry shop towel. CAUTION: When applying adhesive to bore of steering knuckle, do not allow adhesive to get into the snap ring in bore or on the seal of the hub bearing 3. Apply Loctite Adhesive #640 or an equivalent, to the bore of the steering knuckle. The adhesive is to be applied to the entire bore wall surface, from the shoulder at the bottom to just below the snap ring groove. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1244 4. Place new hub bearing into bore of steering knuckle so it is square with the bore. Place steering knuckle in arbor press with Receiver, Special Tool C-4698-2, or equivalent supporting steering knuckle. Place Diver, Special Tool 5052, or equivalent on outer race of the hub bearing. Press hub bearing into steering knuckle until it is fully bottom in bearing bore of steering knuckle. CAUTION: When installing the retaining snap ring for the hub bearing care must be taken not to damage seal on new hub bearing. 5. Install hub bearing retaining snap ring into snap ring groove in hub bearing bore of steering knuckle. Be sure snap ring is fully seated in snap ring groove. 6. Place steering knuckle with hub bearing installed in an arbor press with Receiver, Special Tool MB-990799, or equivalent supporting inner race of the hub bearing. Place hub in nub bearing making sure it is square with bearing. Place Driver, Special Tool 6522, or equivalent on front face of hub. Press the hub into the hub bearing until hub is fully bottomed in hub bearing. 7. Install the steering knuckle, hub and the hub bearing as an assembly on the vehicle. See: Steering and Suspension/Steering/Front Steering Knuckle/Service and Repair 8. Install the wheel and tire on the vehicle. 9. Lower the vehicle. 10. Set the front wheel Toe to the required specification. CAUTION: After the vehicle is aligned it can only be moved a short distance and then parked. Do not move the vehicle any further until the adhesive has cured for a minimum of two hours. Driving the vehicle before the adhesive is allowed to cure properly, will affect the retention of the Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1245 bearing in the bore of the steering knuckle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1246 Wheel Bearing: Service and Repair Rear REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. On vehicles equipped with rear drum brakes, remove brake drum from rear hub/bearing assembly. On vehicles equipped with rear disc brakes, remove disc brake caliper from disc brake adapter, and then remove rotor from hub/ bearing assembly. Rear Hub And Bearing Dust Cap 4. Remove dust cap. from rear hub/bearing assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1247 5. Remove hub/bearing assembly to rear spindle retaining nut. 6. Remove rear hub/bearing assembly from rear spindle by pulling straight of spindle by hand. INSTALL CAUTION: The hub/bearing retaining nut must be tightened to but must not exceed its required torque specification. The proper torque specification of the retaining nut is critical to the life of the hub bearing. 1. Position hub/bearing assembly on rear spindle. 2. Install a new hub nut and tighten to a torque of 217 Nm (160 ft. lbs.). 3. Install dust cap; using a soft faced hammer. 4. On drum brake equipped vehicles, install rear brake drum on hub/bearing assembly. On vehicles equipped with rear disc brakes, install rotor on hub/ bearing assembly. Caliper Assembly Guide Pin Bolts 5. On disc brake equipped vehicles install disc brake caliper on disc brake adapter. Install the 2 caliper guide pin bolts and torque to 22 Nm (192 in. lbs.). Refer To Disc Brake Caliper Service and Repair. 6. Install rear wheel and tire assembly on vehicle. Tighten all wheel stud nuts in crisscross pattern to one-half specified torque. Then repeat pattern, fully tightening stud nuts to 109 - 150 Nm (80 - 110 ft. lbs.). 7. Lower vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 220396 > Oct > 96 > Wheel Covers - Noisy/Missing/Loose Wheel Cover: Customer Interest Wheel Covers - Noisy/Missing/Loose NO: 22-03-96 GROUP: Wheels DATE: Oct. 4, 1996 SUBJECT: Noisy, Loose Or Missing Bolt-on Wheel Covers MODELS: 1997 (PL) Neon SYMPTOM/CONDITION: Noisy, loose or missing wheel covers due to loose or missing wheel cover nuts. DIAGNOSIS: Inspect each wheel cover nut and determine if loose. If the plastic nut is over-torqued, it will result in a jumped thread and become loose. If the plastic nut has jumped a thread torque nut to 55 in. lbs. Inspect the nut, if the nut is loose remove and inspect for damage. If one or more of the 5 nuts is damaged proceed to the repair procedure. If nut is now secure no further action is required. PARTS REQUIRED: AR 04656777 Wheel Cover And Nut Assembly (Sales Code W4W) AR 04656376 Wheel Cover And Nut Assembly (Sales Code W4Y) AR 04656825 Wheel Cover And Nut Assembly (Sales Code W4J) AR 04656251 Wheel Cover And Nut Assembly (Sales Code W4C) REPAIR PROCEDURE: This bulletin provides the procedure for the wheel cover installation. 1. Place wheel cover on wheel and firmly push down on center cap so that it is flat against the wheel. CAUTION: THE WHEEL COVER ATTACHING NUTS SHOULD NEVER BE INSTALLED BY DRIVING THE NUT ONTO THE WHEEL NUT WITH A RUBBER MALLET OR BY USING AN IMPACT WRENCH. PLEASE INSURE THAT THE NEW VEHICLE PREP TECHNICIAN IS AWARE OF THIS INFORMATION. 2. Hand tighten the wheel cover nuts until they begin to "ratchet" and then let the cover spring back. 3. Torque the wheel cover nuts sequentially to between 45 to 55 in. lbs. CAUTION: THE WHEEL COVER NUT HAS A BUILT IN SAFEGUARD THAT WILL ALLOW THE NUT TO JUMP A THREAD IF OVER-TORQUED. IF THIS CONDITION OCCURS, IT THE NUT SHOULD BE TIGHTENED TO JUST BEFORE THE "JUMP" FEATURE. THE "JUMP" FEATURE CAN BE FELT AS A POP WHEN THE NUT IS TORQUED OVER 55 IN. LBS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 22-20-01-93 0.2 Hrs. Inspect and Torque Wheel Cover - One or All FAILURE CODE: XX - Service Adjustment Labor Operation No: 22-20-01-94 0.2 Hrs. Replace Wheel Cover - One or All FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 220396 > Oct > 96 > Wheel Covers Noisy/Missing/Loose Wheel Cover: All Technical Service Bulletins Wheel Covers - Noisy/Missing/Loose NO: 22-03-96 GROUP: Wheels DATE: Oct. 4, 1996 SUBJECT: Noisy, Loose Or Missing Bolt-on Wheel Covers MODELS: 1997 (PL) Neon SYMPTOM/CONDITION: Noisy, loose or missing wheel covers due to loose or missing wheel cover nuts. DIAGNOSIS: Inspect each wheel cover nut and determine if loose. If the plastic nut is over-torqued, it will result in a jumped thread and become loose. If the plastic nut has jumped a thread torque nut to 55 in. lbs. Inspect the nut, if the nut is loose remove and inspect for damage. If one or more of the 5 nuts is damaged proceed to the repair procedure. If nut is now secure no further action is required. PARTS REQUIRED: AR 04656777 Wheel Cover And Nut Assembly (Sales Code W4W) AR 04656376 Wheel Cover And Nut Assembly (Sales Code W4Y) AR 04656825 Wheel Cover And Nut Assembly (Sales Code W4J) AR 04656251 Wheel Cover And Nut Assembly (Sales Code W4C) REPAIR PROCEDURE: This bulletin provides the procedure for the wheel cover installation. 1. Place wheel cover on wheel and firmly push down on center cap so that it is flat against the wheel. CAUTION: THE WHEEL COVER ATTACHING NUTS SHOULD NEVER BE INSTALLED BY DRIVING THE NUT ONTO THE WHEEL NUT WITH A RUBBER MALLET OR BY USING AN IMPACT WRENCH. PLEASE INSURE THAT THE NEW VEHICLE PREP TECHNICIAN IS AWARE OF THIS INFORMATION. 2. Hand tighten the wheel cover nuts until they begin to "ratchet" and then let the cover spring back. 3. Torque the wheel cover nuts sequentially to between 45 to 55 in. lbs. CAUTION: THE WHEEL COVER NUT HAS A BUILT IN SAFEGUARD THAT WILL ALLOW THE NUT TO JUMP A THREAD IF OVER-TORQUED. IF THIS CONDITION OCCURS, IT THE NUT SHOULD BE TIGHTENED TO JUST BEFORE THE "JUMP" FEATURE. THE "JUMP" FEATURE CAN BE FELT AS A POP WHEN THE NUT IS TORQUED OVER 55 IN. LBS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 22-20-01-93 0.2 Hrs. Inspect and Torque Wheel Cover - One or All FAILURE CODE: XX - Service Adjustment Labor Operation No: 22-20-01-94 0.2 Hrs. Replace Wheel Cover - One or All FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Page 1261 Wheel Cover: Description and Operation A lock-on type wheel cover is used on certain models. The wheel cover is locked to the wheel using the 5 nuts located in the wheel cover. The nuts in the wheel cover, thread onto a special externally threaded wheel nut. This is the method used to retain the wheel cover to the wheel. The wheel cover retaining nut is retained in the wheel cover and will stay on the wheel cover when unthreaded from the wheel nut. If required, the retaining nut for the lock-on wheel cover can be removed from the wheel cover and replaced as a separate part of the lock-on wheel cover. The lock-on wheel cover can not be removed from the wheel until all 5 of wheel cover retaining nuts are unthreaded from the wheel nuts. Then the lock-on wheel cover can be removed by hand from the wheel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Wheel Cover Replacement Wheel Cover: Service and Repair Wheel Cover Replacement NOTE: When unthreading the wheel cover retaining nuts from the wheel nuts it is recommended that a hand wrench be used and not an impact wrench. Use of an impact wrench could result in damage to the lock-on wheel cover retaining nuts. REMOVE 1. Unthread the 5 nuts attaching the wheel cover to the wheel nuts. 2. Grasp the wheel cover and pull straight outward from the wheel. This will remove the wheel cover from the wheel. Fig. 2 INSTALL 1. Align the valve notch in the wheel cover with the valve stem on the wheel. Align the wheel cover retaining nuts with the externally threaded wheel nuts. 2. By hand, start to thread all 5 of the wheel cover retaining nuts onto the externally threaded wheel nuts. NOTE: When tightening the wheel cover retaining nuts it is recommended that a hand wrench be used and not an impact wrench. Use of an impact wrench could result in damage to the lock-on wheel cover retaining nuts. 3. Tighten each of the wheel cover retaining nuts. If the retaining nut "jumps" a thread (slips), which is an override feature of the retaining nut, retighten the retaining nut to a point just prior to this occurring. To avoid rattling of the wheel cover be sure all five retaining nuts are correctly tightened. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Wheel Cover Replacement > Page 1264 Wheel Cover: Service and Repair Wheel Cover Retaining Nut Replacement NOTE: If a retaining nut for the lock-on wheel is damaged, it can be replaced as a separate part of the wheel cover. Use the following procedure for replacing a wheel cover retaining nut. REMOVE 1. If required, remove the wheel cover from the wheel. NOTE: The retaining nut flange can not be forced past the large retaining tab. When removing retaining nut from wheel cover, the flange on the retaining nut must be forced past the 2 small retaining tabs on wheel cover. 2. From the back side of the wheel cover, push outward and tilt the retaining nut sideways forcing the flange on the retaining nut past the 2 small retaining tabs in the retaining nut hole of the wheel cover. 3. When flange on retaining nut is past the 2 retaining tabs on the wheel cover, remove retaining nut from wheel cover by pushing or pulling from hole in wheel cover. INSTALL 1. Install retaining nut in hole of wheel cover with retaining nut flange positioned under the large retaining flange. 2. Push on hex of retaining nut forcing the retaining nut flange past the 2 small retaining tabs in wheel cover. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 1274 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 1280 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 1281 Axle Nut: Specifications Front Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 183 Nm (135 ft. lbs.) Rear Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 217 Nm (160 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence Wheel Fastener: Specifications Wheel Tightening Sequence Wheel Torque Sequence - Master Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 1286 Wheel Fastener: Specifications Lug Nut Torque Lug Nuts .............................................................................................................................................. ................................. 109 - 150 Nm (80 - 110 ft. lbs.) Lug Nut Hex Size ............................................. ........................................................................................................................................................... 19 mm Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 1287 Wheel Fastener: Specifications Wheel Stud Size Stud Size ............................................................................................................................................. ............................................................ M12 x 1.5 mm Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1288 Wheel Fastener: Description and Operation If wheel attaching studs need to be replaced in the hub and bearing assembly the studs CAN NOT be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. The hub and bearing assembly does not require removal from the steering knuckle or the rear knuckle to replace the wheel attaching studs in the hub and bearing assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1289 Wheel Fastener: Service and Repair CAUTION: If wheel attaching stud needs to be replaced in the hub and bearing assembly the studs CAN NOT be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. NOTES: - The following procedure and special tools shown MUST be used when replacing wheel attaching studs. - The hub and bearing assembly does not require removal from the steering knuckle to replace wheel attaching studs in the hub and bearing assembly. REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the front wheel and tire assembly from the vehicle. 3. Remove front disc brake caliper to steering knuckle attaching bolts. 4. Remove disc brake caliper assembly from steering knuckle. Caliper is removed by first lifting bottom of caliper away from steering knuckle, and then removing top of caliper out from under steering knuckle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1290 5. Support the brake caliper assembly using a wire hook, not by the hydraulic flex hose. 6. Remove the braking disc from the front hub. 7. Install a lug nut on wheel stud to be removed from hub and bearing assembly, so threads on stud are even with end of lug nut. Rotate hub so stud requiring removal is aligned with notch cast into front of steering knuckle. Install Remover, Special Tool C-4150, or equivalent on hub and bearing assembly flange and wheel stud. 8. Tighten down on special tool, pushing wheel stud out of the hub and bearing assembly flange. When shoulder of wheel stud is past flange remove special tool from hub and bearing assembly. Remove lug nut from stud and remove wheel stud from flange. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1291 INSTALL 1. Install replacement wheel stud into flange of hub and bearing assembly. Install washers and wheel lug nut on stud, with flat side of lug nut against washers. 2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing assembly. When the head of the stud is fully seated against the bearing flange, remove lug nut and washers from wheel stud. 3. Install braking disk back on front hub. 4. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding top of caliper under top abutment on steering knuckle. Then installing bottom of caliper against bottom abutment of steering knuckle. 5. Install the disc brake caliper assembly to steering knuckle attaching bolts and torque to 31 Nm (23 ft. lbs.). 6. Install front wheel and tire assembly. Install front wheel lug nuts and torque to 135 Nm (100 ft. lbs.). 7. Lower vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications COMPRESSION PRESSURE (at 250 - 400 RPM): Standard .............................................................................................................................................. ............................ 1172 - 1551 kPa (170 - 225 psi) Minimum ............................................................. ................................................................................................................................... 689 kPa (100 psi) COMPRESSION PRESSURE DIFFERENCE OF ALL CYLINDER: Maximum ............................................................................................................................................. ....................................................................... 25% VACUUM: Manifold ............................................................................................................................................... .......................................... 60 kPa (18 inches Hg) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1297 Compression Check: Testing and Inspection PROCEDURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire (Conventional Ignition System). For Direct Ignition System (DIS) disconnect the coil connector. 5 . Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adaptor into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is reached on gage. Record this pressure as #1 cylinder pressure. 7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 9. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. 11. Clean or replace spark plugs as necessary and adjust gap. Tighten to specifications. 12. Test resistance of spark plug cables. Perform secondary circuit inspection. 13. Test coil output voltage, primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at idle and different RPM ranges. 15. The air filter elements should be replaced as specified. 16. Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt drives. 18. Road test vehicle as a final test. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Bearing Cap Bolt Torque Camshaft Bearing: Specifications Bearing Cap Bolt Torque Camshaft Bearing Cap ID Camshaft Bearing Cap-Torque Sequence 1. Lubricate bearing journals and cam followers with clean oil and install the camshafts. Install right and left camshaft bearing caps #2 thru #5 and right #6. Tighten M6 fasteners to 12 N.m (105 in. lbs.) in sequence. Camshaft Bearing Cap Sealing 2. Apply Mopar Gasket Maker to No.1 and No.6 bearing caps. Jnstall bearing caps and tighten M8 fasteners to 24 N.m (215 in. lbs.). 3. Bearing cap number 1, must be installed before the camshaft seals can be installed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Bearing Cap Bolt Torque > Page 1303 Camshaft Bearing: Specifications Engine Rebuild Specifications Bearing Bore Diameter No.1-6 ............................................................................................................................. 26.020 - 26.041 mm (1.024 - 1.025 inch) Diametrical Bearing Clearance ............................................................................................................................... 0.069 - 0.071 mm (0.0027 - 0.003 inch) Max. Allowable ............................................................................................................................................................. 0.05 - 0.15 mm (0.002 - 0.006 inch) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Sprocket Bolt ....................................................................................................................................... .................................................. 115 Nm (85 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Page 1307 Camshaft Gear/Sprocket: Tools and Equipment Camshaft Sprocket Remover/Installer C-4687 Camshaft Sprocket Remover/Installer Adapter C-4687-1 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Bearing Cap Bolt Torque Camshaft: Specifications Bearing Cap Bolt Torque Camshaft Bearing Cap ID Camshaft Bearing Cap-Torque Sequence 1. Lubricate bearing journals and cam followers with clean oil and install the camshafts. Install right and left camshaft bearing caps #2 thru #5 and right #6. Tighten M6 fasteners to 12 N.m (105 in. lbs.) in sequence. Camshaft Bearing Cap Sealing 2. Apply Mopar Gasket Maker to No.1 and No.6 bearing caps. Jnstall bearing caps and tighten M8 fasteners to 24 N.m (215 in. lbs.). 3. Bearing cap number 1, must be installed before the camshaft seals can be installed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Bearing Cap Bolt Torque > Page 1312 Camshaft: Specifications Rebuild Specifications Bearing Bore Diameter ......................................................................................................................................... 26.020 26.041 mm (1.024 - 1.025 inch) Diametrical Bearing Clearance ............................................................................................................................. 0.069 - 0.071 mm (0.0027 - 0.0030 inch) End Play .......................................................................................................... .............................................................. 0.05 - 0.15 mm (0.002 - 0.006 inch) Bearing Journal Diameter ...................................................................................................................................... 25.951 - 25.970 mm (1.021 - 1.022 inch) LIFT: Intake ................................................................................................................................................... ............................................ 8.75 mm (0.344 inch) Exhaust ................................................................ ............................................................................................................................ 8.00 mm (0.314 inch) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1313 Camshaft: Description and Operation GENERAL INFORMATION The nodular iron camshafts have six bearing journals and 2 cam lobes per cylinder. END PLAY CONTROL Flanges at the rear journals control camshaft end play. CAM POSITION SENSOR Provision for cam position sensor is located on the intake camshaft at the rear of cylinder head. OIL SEAL A hydrodynamic oil seal is used for oil control at the front of the camshaft. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Removal and Installation Camshaft: Service and Repair Removal and Installation REMOVAL 1. Remove cylinder head cover. 2. Remove timing belt, sprockets and covers. 3. Bearing caps are identified for location. Remove the outside bearing caps first. 4. Loosen the camshaft bearing cap attaching fasteners in sequence shown one camshaft at a time. CAUTION: Camshafts are not interchangeable. The intake cam number 6 thrust bearing face spacing is wider. 5. Identify the camshafts before removing from the head. The camshafts are not interchangeable. NOTE: - Check Camshaft for binding in cylinder head. Inspect camshaft bearing journals for damage. If camshafts are binding, also check the cylinder head bearing surface for damage, and check the camshaft bearing oil feed holes in the cylinder head for clogging. - Check the cam surface for abnormal wear and damage, replace if defective. A visible worn groove in the roller follower or on the cam lobes is cause for replacement. CAUTION: Ensure that NONE of the pistons are at top dead center when installing the camshafts. INSTALLATION 1. Lubricate bearing journals and cam followers with clean oil and install the camshafts. Install right and left camshaft bearing caps #2 thru #5 and Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1316 right #6. Tighten M6 fasteners to 12 Nm (105 inch lbs.) in sequence shown. 2. Apply Mopar Gasket Maker, or equivalent to No. 1 and No. 6 bearing caps. Install bearing caps and tighten M8 fasteners to 24 Nm (215 inch lbs.) . 3. Bearing cap number 1, must be installed before the camshaft seals can be installed. 4. Install timing belt, sprockets and covers. 5. Install cylinder head cover. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1317 Camshaft: Service and Repair Checking End Play END PLAY 1. Oil camshaft journals and install camshaft WITHOUT cam follower assemblies. Install rear cam caps and tighten screws to specified torque. 2. Using a suitable tool, move camshaft as far rearward as it will go. 3. Zero dial indicator. 4. Move camshaft as far forward as it will go. 5. End play travel: 0.05 - 0.15 mm (0.002 - 0.06 inch). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection Lifter / Lash Adjuster: Testing and Inspection A tappet-like noise may be produced from several items. Check the following items. 1. Engine oil level too high or too low. This may cause aerated oil to enter the adjusters and cause them to be spongy. 2. Insufficient running time after rebuilding cylinder head. Low speed running up to 1 hour may be required. 3. During this time, turn engine off and let set for a few minutes before restarting. Repeat this several times after engine has reached normal operating temperature. 4. Low oil pressure. 5. The oil restrictor pressed into the vertical oil passage to the cylinder head is plugged with debris. 6. Air ingested into oil due to broken or cracked oil pump pick up. 7. Worn valve guides. 8. Rocker arm ears contacting valve spring retainer. 9. Rocker arm loose, adjuster stuck or at maximum extension and still leaves lash in the system. 10. Faulty lash adjuster. a. Check lash adjusters for sponginess while installed in cylinder head. Depress part of rocker arm over adjuster. Normal adjusters should feel very firm. Spongy adjusters can be bottomed out easily. b. Remove suspected lash adjusters, and replace. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Cam Follower <--> [Rocker Arm Assembly] > Component Information > Service and Repair Cam Follower: Service and Repair REMOVAL 1. Remove valve cover using. 2. Remove timing belt, sprockets and covers. 3. Remove camshaft. 4. Remove cam follower assemblies from cylinder head. Keep the cam followers in the order they have been removed from the head for reassembly. Mark hydraulic lash adjusters for reassembly in their original position. Lash adjusters are serviced as a assembly. NOTE: Inspect the cam follower assembly for wear or damage. Replace as necessary. INSTALLATION 1. Install hydraulic lash adjuster assembly making sure that adjusters are at least partially full of oil. This is indicated by little or no plunger travel when the lash adjuster is Lubricated with clean oil and install cam follower assemblies in their original position on the hydraulic adjuster and valve stem. 2. Install the camshafts. NOTE: - A tappet like noise may be produced from several items. - Hydraulic Lash adjusters are replaced as an assembly and are not repaired. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1328 Connecting Rod Bearing: Service and Repair Engine connecting rod bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage: 1. Rotate the crankshaft until the connecting rod to be checked is at the bottom of its stroke. 2. Remove oil film from surface to be checked. Plastigage is soluble in oil. 3. Place a piece of Plastigage across the entire width of the bearing shell in the bearing cap approximately 6.35 mm (1/4 inch) off center and away from the oil hole. In addition, suspect areas can be checked by placing plastigage in the suspect area. 4. Before assembling the rod cap with Plastigage in place, the crankshaft must be rotated until the connecting being checked starts moving toward the top of the engine. Only then should the cap be assembled and torqued to specifications. Do not rotate the crankshaft while assembling the cap or the Plastigage may be smeared, giving inaccurate results. 5. Remove the bearing cap and compare the width of the flattened Plastigage with the scale provided on the package. Locate the band closest to the same width. This band indicates the amount of oil clearance. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Refer to Specifications. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Cap Bolts/Nuts Connecting Rod: Specifications Connecting Rod Cap Bolts/Nuts Connecting rod cap bolt ..................................................................................................................................... 27 Nm + 90° turn (20 ft. lbs. + 90° turn) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Cap Bolts/Nuts > Page 1333 Connecting Rod: Specifications Connecting Rod Specifications Piston Pin Bore Diameter ...................................................................................................................................... 20.96 - 20.98 mm (0.8252 - 0.8260 inch) Large End Bore Diameter ................................................................................................................................. 50.991 - 51.005 mm (2.0075 - 2.0081 inch) Side Clearance ......................................................................................... ...................................................................... 0.13 - 0.38 mm (0.005 - 0.015 inch) Total Weight (Less Bearing) ..................................................................................................................................... ........................... 543 grams (1.20 lbs.) Mounting Bolt ........................................................................ ............................................................................................ 27 Nm (20 ft. lbs.) Plus 1/4 Turn Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1334 Connecting Rod: Description and Operation This engine DOES NOT have provision for a free wheeling valve train. Non free wheeling valve train means, in the event of a broken timing belt Pistons will contact the Valves. All engines use pressed-in piston pins to attach forged powdered metal connecting rods. The connecting rods are a cracked cap design and are not repairable. Hex head cap screw are used to provide alignment and durability in the assembly. NOTE: Pistons And Connecting rods are serviced as an assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Removal and Installation Connecting Rod: Service and Repair Removal and Installation REMOVAL 1. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Mark piston with matching cylinder number. 2. Remove oil pan. Scribe the cylinder number on the side of the rod and cap for identification. 3. Pistons will have a stamping in the approximate location shown. These stamps will be either a directional arrow or a weight identification for the assembly. L is for light and H is for heavy. These assemblies should all be the same weight class. Service piston assemblies are marked with a S and can be used with either L or H production assemblies. The weight designation stamps should face toward the timing belt side of the engine. 4. Pistons and connecting rods must be removed from top of cylinder block. Rotate crankshaft so that each connecting rod is centered in cylinder bore. 5. Remove connecting rod cap bolts Do not use old bolts if reinstalling connecting rod. Push each piston and rod assembly out of cylinder bore. NOTE: Be careful not to nick crankshaft journals. 6. After removal, install bearing cap on the mating rod. 7. Piston and Rods are serviced as an assembly. INSTALLATION 1. Before installing pistons and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Removal and Installation > Page 1337 2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located as shown. 3. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston. Be sure position of rings does not change during this operation. 4. The weight stamp designation L or H will be in the front half of the piston should face toward the front of the engine. 5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston assembly into cylinder bore and guide rod over the crankshaft journal. 6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. 7. Install rod caps. Install New bolts and tighten to 27 Nm (20 ft.lb.) Plus 1/4 turn. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Removal and Installation > Page 1338 Connecting Rod: Service and Repair Fitting Connecting Rod 1. Follow the procedure specified in Connecting Rod Bearing for Connecting Rod Bearing Clearance. Refer to specifications. CAUTION: Do not rotate crankshaft or the Plastigage may be smeared. NOTE: The rod bearing bolts should not be reused. 2. Before installing the NEW bolts the threads should be oiled with clean engine oil. 3. Install each bolt finger tight then alternately torque each bolt to assemble the cap properly. 4. Tighten the bolts to 27 Nm PLUS 1/4 turn (20 ft. lbs. PLUS 1/4 turn) Do not use a torque wrench for last step. 5. Using a feeler gauge, check connecting rod side clearance. Refer to connecting rod specifications. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Description and Operation Crankshaft Gear/Sprocket: Description and Operation GENERAL INFORMATION A sintered iron timing belt sprocket is mounted on the crankshaft nose. This sprocket transmits crankshaft movement, via timing belt to the camshaft sprocket providing timed valve actuation. BOLT ACCESS PLUG An Access plug is located in the right inner fender shield. Remove the plug and insert the proper size socket, extension and ratchet, when crankshaft rotation is necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Description and Operation > Page 1342 Crankshaft Gear/Sprocket: Tools and Equipment Crankshaft Sprocket Remover 6793 Crankshaft Sprocket Installer 6792 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Rebuild Specifications Crankshaft Main Bearing: Specifications Rebuild Specifications Main bearing journal diameter .................................................................................................................. 51.9924 - 52.0076 mm (2.0469 - 2.0475 inch) Main bearing journal out-of-roundness ...................................................................................................................................... 0.0035 mm (0.0001 inch) Main bearing journal taper ......................................................................................................................................................... 0.0038 mm (0.0001 inch) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Rebuild Specifications > Page 1347 Crankshaft Main Bearing: Specifications Torque Specifications M8 Bedplate Bolts ............................................................................................................................... ..................................................... 30 Nm (22 ft. lbs.) M11 Main Cap Bolts ......................................... ....................................................................................................................................... 81 Nm (60 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1348 Crankshaft Main Bearing: Description and Operation The crankshaft is supported in five main bearings. All upper bearing shells in the crankcase have oil grooves. All lower bearing shells installed in the (bedplate) main bearing cap are plain. Crankshaft end play is controlled by a flanged bearing on the number three main bearing journal. NOTE: The upper and lower main Bearing shells are Not interchangeable: The lower shells have a revised tab to prevent improper installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1349 Crankshaft Main Bearing: Service and Repair PLASTIGAGE METHOD Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage: NOTE: The total clearance of the main bearings can only be determined by removing the weight of the crankshaft. This can be accomplished by either of two methods: Preferred Method Shimming the bearings adjacent to the bearing to be checked in order to remove the clearance between upper bearing shell and the crankshaft. This can be accomplished by placing a minimum of 0.254 mm (0.010 inch) shim (e.g. cardboard, match-book cover, etc.) between the bearing shell and the bearing cap on the adjacent bearings and tightening bolts to 14 20 Nm (10 - 15 ft. lbs.). The number of main bearing will vary from engine to engine. - When checking #1 main bearing shim #2 main bearing. - When checking #2 main bearing shim #1 & main bearing. - When checking #3 main bearing shim #2 & 4 main bearing. - When checking #4 main bearing shim #3 & 5 main bearing. - When checking #5 main bearing shim #4 main bearing. CAUTION: Remove all shims before reassembling engine. Alternative Method The weight of the crankshaft can be supported by a jack under the counterweight adjacent to the bearing being checked. PLASTIGAGE PROCEDURE 1. Remove oil film from surface to be checked. Plastigage is soluble in oil. 2. Place a piece of Plastigage across the entire width of the bearing shell in the cap approximately 6.35 mm (1/4 inch) off center and away from the oil holes. (In addition, suspected areas can be checked by placing the Plastigage in the suspected area). Torque the bearing cap bolts of the bearing being checked to the proper specifications. 3. Remove the bearing cap and compare the width of the flattened Plastigage with the metric scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance in thousandths of a millimeter. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Out-of-Round (Max.): 0.0035 mm (0.0001 inch) Taper (Max.): 0.0038 mm (0.0001 inch) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1353 Crankshaft: Description and Operation CONSTRUCTION A nodular cast iron crankshaft is used. The engine has 5 main bearings, with number 3 flanged to control thrust. The 52 mm diameter main and 48 mm diameter crank pin journals (all) have undercut fillet radiuses that are deep rolled for added strength. To optimize bearing loading 8 counterweights are used. SEALING Hydrodynamic seals provide end sealing, where the crankshaft exits the block. Anaerobic gasket material is used for parting line sealing. SPROCKET A sintered iron timing belt sprocket is mounted on the crankshaft nose. This sprocket transmits crankshaft movement, via timing belt to the camshaft sprocket providing timed valve actuation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation Crankshaft: Service and Repair Removal and Installation REMOVAL 1. Remove oil filter and adapter from bedplate. 2. Remove oil pan. 3. Remove crankshaft sprocket and oil pump. 4. Remove all main bearing cap and bedplate bolts from the engine block. 5. Using a mallet tap the bedplate loose from the engine block dowel pins. CAUTION: Do not pry up on one side of the bedplate. Damage may occur to cylinder block and bedplate alignment. 6. Bedplate should be removed evenly from the cylinder block dowel pins. 7. Lift out crankshaft from cylinder block. Be sure not to damage the main bearings or journals when removing the crankshaft. INSTALLATION 1. Install the main bearing shells with the lubrication groove in the cylinder block. Install O-ring into recess in the block. 2. Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the block tab slots. CAUTION: Do Not get oil on the bedplate mating surface. It will affect the sealer ability to seal the bedplate to cylinder block. 3. Oil the bearings and journals and install crankshaft and O-ring in cylinder block. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1356 CAUTION: Use only the specified anaerobic sealer on the bedplate or damage may occur to the engine. 4. Apply 1.5 - 2.0 mm (0.059 - 0.078 inch) bead of Mopar Torque Cure Gasket Maker to cylinder block as shown. 5. Install lower main bearings into main bearing cap/bedplate. Make certain the bearing tabs are seated into the bedplate slots. Install the main bearing/bedplate into engine block. 6. Before installing the bolts the threads should be oiled with clean engine oil, wipe off any excess oil. 7. Install main bearing bedplate to engine block bolts 11, 17 and 20 finger tight. Tighten this bolts down together until the bedplate contacts the cylinder block. Torque bolts to 30 Nm (22 ft. lbs.). 8. Install main bearing bedplate to engine block bolts (1 thru 10) and torque each bolt to 81 Nm (60 ft. lbs.) in sequence shown. 9. Install main bearing bedplate to engine block bolts (11 thru 20), with baffle studs in positions 12, 13 and 16 and torque each bolt to 30 Nm (22 ft. lbs.) in sequence shown. 10. After the main bearing bedplate is installed, check the crankshaft turning torque. The turning torque should not exceed 5.6 Nm (50 inch lbs.). 11. Install oil pump and check crankshaft end play. 12. Install crankshaft sprocket. 13. Install oil filter adapter and filter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1357 Crankshaft: Service and Repair Service Procedures Crankshaft End Play Measurement DIAL INDICATOR METHOD 1. Mount a dial indicator to front of engine, locating probe on nose of crankshaft. 2. Move crankshaft all the way to the rear of it travel. 3. Zero the dial indicator. 4. Move crankshaft all the way to the front ant read the dial indicator. Refer to specifications. FEELER GAGE METHOD 1. Move crankshaft all the way to the rear of its travel using a lever inserted between a main bearing cap and a crankshaft cheek, using care not to damage any bearing surface. Do not loosen main bearing cap. 2. Use a feeler gauge between number three thrust bearing and machined crankshaft surface to determine end play. Journal Inspection Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1358 The crankshaft journals should be checked for excessive wear, taper and scoring. Limits of taper or out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 inch). Journal grinding should not exceed 0.305 mm (0.012 inch) under the standard journal diameter. DO NOT grind thrust faces of Number 3 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all passages. CAUTION: With the nodular cast iron crankshafts used it is important that the final paper or cloth polish after any journal regrind be in the same direction as normal rotation in the engine. Upper and lower Number 3 bearing halves are flanged to carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves in the engine. All bearing cap bolts removed during service procedures are to be cleaned and oiled before installation. Bearing shells are available in standard and the following undersized: 0.016 mm (0.0006 inch), 0.032 mm (0.0012 inch), 0.250 mm (0.010 inch). Never install an undersize bearing that will reduce clearance below specifications. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation Engine Block Heater: Description and Operation The heater, operated by ordinary house current (110 Volt A.C.) through a power cord and connector behind the radiator grille, provides easier engine starting and faster warm-up when vehicle is operated in areas having extremely low temperatures. The heater is mounted in a core hole (in place of a core hole plug) in the engine block, with the heating element immersed in coolant. NOTE: The power cord must be secured in its retainer clips, and not positioned so it could contact linkages or exhaust manifolds and become damaged. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1362 Engine Block Heater: Testing and Inspection If unit does not operate, trouble can be in either the power cord or the heater element. Test power cord for continuity with a 110-volt voltmeter or 110volt test light; test heater element continuity with an ohmmeter or 12-volt test light. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1363 Engine Block Heater: Service and Repair REMOVAL 1. Drain coolant from radiator and cylinder block. 2. Detach power cord plug from heater. 3. Loosen screw in center of heater. Remove heater assembly. INSTALLATION 1. Thoroughly clean core hole and heater seat. 2. Insert heater assembly with element loop positioned upward. 3. With heater seated, tighten center screw securely to assure a positive seal. 4. Fill cooling system with coolant to the proper level, vent air, and inspect for leaks. Pressurize system with Radiator Pressure Tool before looking for leaks. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Core Plug <--> [Expansion/Freeze Plug] > Component Information > Service and Repair Core Plug: Service and Repair REMOVAL Using a blunt tool such as a drift or a screwdriver and a hammer, strike the bottom edge of the cup plug. With the cup plug rotated, grasp firmly with pliers or other suitable tool and remove plug. CAUTION: Do not drive cup plug into the casting as restricted cooling can result and cause serious engine Problems. INSTALLATION Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer. Lightly coat inside of cup plug hole with sealer. Make certain the new plug is cleaned of all oil or grease. Using proper drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5 mm (0.020 inch) inside the lead in chamfer. It is in not necessary to wait for curing of the sealant. The cooling system can be refilled and the vehicle placed in service immediately. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Torque Torque Crankshaft Pulley Bolt 105 ft.lb Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1370 Harmonic Balancer - Crankshaft Pulley: Service and Repair NOTE: If a gap is found in the crankshaft damper, in the area where the Poly-V Generator belt rides this is normal and is acceptable. REMOVAL 1. Remove accessory drive belts. 2. Raise vehicle on a hoist and remove right inner splash shield. 3. Remove crankshaft damper bolt. Remove damper using the large side of Special Tool 1026 and insert 6827-A. or equivalents. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1371 INSTALLATION 1. Install crankshaft damper using M12-1.75 x 150 mm bolt, washer, thrust bearing and nut from Special Tool 6792, or equivalent. Install crankshaft damper bolt and tighten to 142 Nm (105 ft. lbs.). 2. Install accessory drive belts. 3. Raise vehicle on hoist and install right inner splash shield. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1372 Harmonic Balancer - Crankshaft Pulley: Tools and Equipment Puller 1026 Crankshaft Damper Removal Insert 6827-A Crankshaft Damper Installer 6792 Crankshaft Damper Installer C-4685-C Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Clearance ............................................................................................................................................ .................... 0.018 - 0.050 mm (0.0007 - 0.0020inch) Weight ............................................................ ......................................................................................................... 340 - 350 grams (11.99 - 12.34 ounces) Head Land Clearance ................................................................................................................................................ 0.740 0.803 mm (0.029 - 0.031 inch) PISTON RING GROOVE DEPTH No. 1 .................................................................................................................................................... .................. 3.983 - 4.132 mm (0.157 - 0.163 inch) No. 2 .................................................................... .................................................................................................. 4.456 - 4.605 mm (0.175 - 0.181 inch) No. 3 ........................................................................................................................................... ........................... 3.841 - 4.075 mm (0.151 - 0.150 inch) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1376 Piston: Description and Operation This engine DOES NOT have provision for a free wheeling valve train. Non free wheeling valve train means, in the event of a broken timing belt Pistons will contact the Valves. All engines use pressed-in piston pins to attach forged powdered metal connecting rods. The connecting rods are a cracked cap design and are not repairable. Hex head cap screw are used to provide alignment and durability in the assembly. NOTE: Pistons And Connecting rods are serviced as an assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation Piston: Service and Repair Removal and Installation REMOVAL 1. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Mark piston with matching cylinder number. 2. Remove oil pan. Scribe the cylinder number on the side of the rod and cap for identification. 3. Pistons will have a stamping in the approximate location shown. These stamps will be either a directional arrow or a weight identification for the assembly. L is for light and H is for heavy. These assemblies should all be the same weight class. Service piston assemblies are marked with a S and can be used with either L or H production assemblies. The weight designation stamps should face toward the timing belt side of the engine. 4. Pistons and connecting rods must be removed from top of cylinder block. Rotate crankshaft so that each connecting rod is centered in cylinder bore. 5. Remove connecting rod cap bolts Do not use old bolts if reinstalling connecting rod. Push each piston and rod assembly out of cylinder bore. NOTE: Be careful not to nick crankshaft journals. 6. After removal, install bearing cap on the mating rod. 7. Piston and Rods are serviced as an assembly. INSTALLATION 1. Before installing pistons and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1379 2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located as shown. 3. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston. Be sure position of rings does not change during this operation. 4. The weight stamp designation L or H will be in the front half of the piston should face toward the front of the engine. 5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston assembly into cylinder bore and guide rod over the crankshaft journal. 6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. 7. Install rod caps. Install New bolts and tighten to 27 Nm (20 ft.lb.) Plus 1/4 turn. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1380 Piston: Service and Repair Fitting Pistons Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin about 17.5 mm (11/16 inch) from the bottom of the skirt as shown. Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line shown. Correct piston to bore clearance must be established in order to assure quiet and economical operation. NOTE: - Chrysler engines use pistons designed specifically for each engine model. Clearance and sizing locations vary with respect to engine model. - Pistons and cylinder bores should be measured at normal room temperature, 21°C (70°F). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Clearance in Piston ................................................................................................................................................ 0.008 0.020 mm (0.0003 - 0.0008 inch) In Rod (Interference) ............................................................................................................................................. 0.018 0.043 mm (0.0007 - 0.0017 inch) Diameter ............................................................................................................................................................ 20.998 - 21.003 mm (0.8267 - 0.8269 inch) End Play ......................................................................... ............................................................................................................................................... None Length .................................................................................................................................................. ..................... 74.75 - 75.25 mm (2.943 - 2.963 inch) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications END GAP: Top Compression Ring ............................................................................................................................................. 0.23 0.52 mm (0.009 - 0.020 inch) 2nd Compression Ring .............................................................................................................................................. 0.49 0.78 mm (0.019 - 0.031 inch) Oil Control Steel Rails .............................................................................................................................................. 0.23 0.66 mm (0.009 - 0.026 inch) SIDE GROOVE CLEARANCE: Compression Rings ........................................................................................................................................... 0.025 0.065 mm (0.0010 - 0.0026 inch) Oil Ring Pack .................................................................................................................................................... 0.004 - 0.178 mm (0.0002 - 0.0070 inch) RING WIDTH: Compression Rings ................................................................................................................................................... 1.17 1.19 mm (0.046 - 0.047 inch) Oil Ring Pack .................................................................................................................................................... 2.854 - 3.008 mm (0.1124 - 0.1184 inch) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1387 Piston Ring: Description and Operation The piston rings include a molybdenum faced top ring for reliable compression sealing and a taper faced intermediate ring for additional cylinder pressure control. Oil Control Ring Package consist of 2 steel rails and a expander spacer. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Removal and Installation Piston Ring: Service and Repair Removal and Installation REMOVAL 1. ID mark on face of upper and intermediate piston rings must point toward piston crown. 2. Using a suitable ring expander, remove upper and intermediate piston rings. 3. Remove the upper oil ring side rail, lower oil ring side rail and then oil ring expander from piston. 4. Clean ring grooves of any carbon deposits. INSTALLATION 1. Install rings with manufacturers I.D. mark facing up, to the top of the piston. CAUTION: Install piston rings in the following order: a. Oil ring expander. b. Upper oil ring side rail. c. Lower oil ring side rail. d. No. 2 Intermediate piston ring. e. No. 1 Upper piston ring. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Removal and Installation > Page 1390 f. Install the side rail by placing one end between the piston ring groove and the expander. Hold end firmly and press down the portion to be installed until side rail is in position. Do not use a piston ring expander. 2. Install upper side rail first and then the lower side rail. 3. Install No. 2 piston ring and then No. 1 piston ring. 4. Position piston ring end gaps as shown in. 5. Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is important for oil control. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Removal and Installation > Page 1391 Piston Ring: Service and Repair Fitting Piston Rings END GAP Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 inch) from bottom of cylinder bore. Check gap with feeler gauge. SIDE GROOVE CLEARANCE Check piston ring to groove side clearance. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates this engine is equipped with hydraulic lifters or lash adjusters and therefore does not require adjustment. See "Rocker Arm: Service and Repair" for further information. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 1399 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 12 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) 6. Replace Pressure test port cap when finished releasing pressure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Cam Follower <--> [Rocker Arm Assembly] > Component Information > Service and Repair Cam Follower: Service and Repair REMOVAL 1. Remove valve cover using. 2. Remove timing belt, sprockets and covers. 3. Remove camshaft. 4. Remove cam follower assemblies from cylinder head. Keep the cam followers in the order they have been removed from the head for reassembly. Mark hydraulic lash adjusters for reassembly in their original position. Lash adjusters are serviced as a assembly. NOTE: Inspect the cam follower assembly for wear or damage. Replace as necessary. INSTALLATION 1. Install hydraulic lash adjuster assembly making sure that adjusters are at least partially full of oil. This is indicated by little or no plunger travel when the lash adjuster is Lubricated with clean oil and install cam follower assemblies in their original position on the hydraulic adjuster and valve stem. 2. Install the camshafts. NOTE: - A tappet like noise may be produced from several items. - Hydraulic Lash adjusters are replaced as an assembly and are not repaired. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Cylinder Head Cover Bolts 105 in.lb Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Page 1406 Valve Cover: Service Precautions CAUTION: Do not allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Page 1407 Valve Cover: Service and Repair REMOVAL 1. Remove ignition coil pack. 2. Remove the cylinder head cover fasteners. 3. Remove cylinder head cover from cylinder head. NOTE: Before installation, clean cylinder head and cover mating surfaces. Make certain the rails are flat. INSTALLATION 1. Install new cylinder head cover gaskets. CAUTION: Do not allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping. 2. Apply Mopar Silicone Rubber Adhesive Sealant at the camshaft cap corners and at the top edges of the 1/2 round seal. 3. Install cylinder head cover assembly to head and tighten fasteners in sequence shown. Using the 3 step torque method: - Step 1 Tighten all fasteners to 4.5 Nm (40 inch lbs.) - Step 2 Tighten all fasteners to 9.0 Nm (80 inch lbs.) - Step 3 Tighten all fasteners to 12 Nm (105 inch lbs.) 4. Install ignition coil pack. Tighten fasteners to 12 Nm (105 inch lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 1411 Valve Guide: Description and Operation Incorporates powder metal valve guides. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 1412 Valve Guide: Service and Repair 1. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. 2. Using a small hole gauge and a micrometer, measure valve guides in 3 places top, middle and bottom. Refer to specifications. Replace guides if they are not within specification. 3. Check valve guide height. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Angle ................................................................................................................................................... ................................................................ 44 1/2 - 45° Runout (Max.) ...................................................................................................................................... ............................................. 0.050 mm (0.002 inch) Width (Finish) Intake and Exhaust .................................................................................................................................... 0.9 - 1.3 mm (0.035 - 0.051 inch) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications > Page 1416 Valve Seat: Description and Operation Incorporates powder metal seats. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications > Page 1417 Valve Seat: Service and Repair 1. When refacing valve seats, it is important the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained. 2. Measure the concentricity of valve seat and valve guide using a valve seat runout dial indicator. Total runout should not exceed 0.051 mm (0.002 inch) (total indicator reading). 3. Inspect the valve seat with Prussian blue to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian blue then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is transferred to top edge of the valve face, lower valve seat with a 15 degrees stone. If the blue is transferred to the bottom edge of valve face raise valve seat with a 65 degrees stone. - Intake valve seat diameter is 34.37 - 34.63 mm (1.353 - 1.363 inch) - Exhaust valve seat diameter is 29.37 - 29.63 mm (1.156 - 1.166 inch) 4. Valve seats which are worn or burned can be reworked, provided that correct angle and seat width are maintained. The intake valve seat must be serviced when the valve seat width is 2.0 mm (0.079 inch) or greater. The exhaust valve seat must be serviced when the valve seat width is 2.5 mm (0.098 inch) or greater. Otherwise the cylinder head must be replaced. 5. When seat is properly positioned the width of intake and exhaust seats should be 0.90 - 1.30 mm (0.035 - 0.051 inch). 6. Check valve tip to spring seat dimensions A after grinding the valve seats or faces. Grind valve tip to 47.99 mm (1.889 inch) for exhaust valve and 48.04 mm (1.891 inch) for intake valve over spring seat when installed in the head. The valve tip chamfer may need to be reground to prevent seal damage when the valve is installed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Technical Service Bulletins > Customer Interest for Valve Spring: > 18-18-99 > Aug > 99 > Engine - MIL ON Misfire DTC's Stored Valve Spring: Customer Interest Engine - MIL ON Misfire DTC's Stored NUMBER: 18-18-99 GROUP: Vehicle Performance DATE: Aug. 13, 1999 SUBJECT: Multiple Cylinder Misfire Due to Carbon Deposits OVERVIEW: This bulletin involves verifying PCM software and installing revised valve springs. MODELS: 1997 - 1999 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L DOHC ENGINE BUILT PRIOR TO NOVEMBER 3, 1998 (MDH 11O3XX). SYMPTOM/CONDITION: Engine roughness/misfire usually only apparent on initial cold engine start. May be accompanied by a MIL illumination for SINGLE or MULTIPLE CYLINDER MISFIRE DTC's. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and/or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If non-misfire related DTC's are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If SINGLE or MULTIPLE CYLINDER MISFIRE DTC's are present, follow all misfire diagnostics listed in the appropriate Diagnostic Procedures Manual and verify TSB 18-47-98 has been completed before performing this Repair Procedure. PARTS REQUIRED: 16 04777555AB Valve Spring REPAIR PROCEDURE: 1. Replace all Valve springs as described on page 9-83 of the 1999 Neon service manual (Publication No. 81-270-0125). NOTE: ALL VALVE SPRINGS MUST BE REPLACED ASA SET WHEN INSTALLING THE REVISED SPRING. FOR REFERENCE, THE REVISED SPRING IS 49.3 MM (+/- 1 MM) IN LENGTH WITH A SINGLE GREEN OR YELLOW STRIPE. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 09-95-20-93 3.8 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Spring: > 18-18-99 > Aug > 99 > Engine - MIL ON Misfire DTC's Stored Valve Spring: All Technical Service Bulletins Engine - MIL ON Misfire DTC's Stored NUMBER: 18-18-99 GROUP: Vehicle Performance DATE: Aug. 13, 1999 SUBJECT: Multiple Cylinder Misfire Due to Carbon Deposits OVERVIEW: This bulletin involves verifying PCM software and installing revised valve springs. MODELS: 1997 - 1999 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L DOHC ENGINE BUILT PRIOR TO NOVEMBER 3, 1998 (MDH 11O3XX). SYMPTOM/CONDITION: Engine roughness/misfire usually only apparent on initial cold engine start. May be accompanied by a MIL illumination for SINGLE or MULTIPLE CYLINDER MISFIRE DTC's. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and/or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If non-misfire related DTC's are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If SINGLE or MULTIPLE CYLINDER MISFIRE DTC's are present, follow all misfire diagnostics listed in the appropriate Diagnostic Procedures Manual and verify TSB 18-47-98 has been completed before performing this Repair Procedure. PARTS REQUIRED: 16 04777555AB Valve Spring REPAIR PROCEDURE: 1. Replace all Valve springs as described on page 9-83 of the 1999 Neon service manual (Publication No. 81-270-0125). NOTE: ALL VALVE SPRINGS MUST BE REPLACED ASA SET WHEN INSTALLING THE REVISED SPRING. FOR REFERENCE, THE REVISED SPRING IS 49.3 MM (+/- 1 MM) IN LENGTH WITH A SINGLE GREEN OR YELLOW STRIPE. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 09-95-20-93 3.8 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Technical Service Bulletins > Page 1431 Valve Spring: Specifications Free Length ......................................................................................................................................... .................................................... 46 mm (1.811 inch) Spring Tension: Valve Closed ................................................................................................................................... 246 - 270 N @ 38.0 mm (55 - 60 lbs. @ 1.496 inch) Valve Open .................................................................................................................................... 549 - 611 N @ 29.3 mm (123 - 137 lbs. @ 1.53 inch) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head Off Valve Spring: Service and Repair Cylinder Head Off REMOVAL 1. With cylinder head removed, compress valve springs using Special Tool MD 998735 or equivalent. 2. Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. 3. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure installation in original location. INSTALLATION 1. Coat valve stems with clean engine oil and insert in cylinder head. 2. Install new valve stem seals on all valves using a valve stem seal tool. The valve stem seals should be pushed firmly and squarely over valve guide. CAUTION: If oversize valves are used, there is only one oversize valve available. The same stem seal is used on both the standard and oversize valve. 3. Install valve springs and retainers. Compress valve springs only enough to install locks, taking care not to misalign the direction of compression. Nicked valve stems may result from misalignment of the valve spring compressor. CAUTION: When depressing the valve spring retainers with valve spring compressor the locks can become dislocated. Check to make sure both locks are in their correct location after removing tool. 4. Check the valve spring installed height B after refacing the valve and seat. Make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 38.75 mm (1.525 inch), install 7.620 mm (0.030 inch) spacer under the valve spring seat to bring spring height back within specification. 5. Install cam followers and camshaft. 6. Checking dry lash. Dry lash is the amount of clearance that exists between the base circle of an installed cam and the rocker arm roller when the adjuster is drained of oil and completely collapsed. NOTE: Specified dry lash is 1.17 mm (0.046 inch) for intake and 1.28 mm (0.050 inch) for exhaust. After performing dry lash check, refill adjuster with oil and allow 10 minutes for adjuster or adjusters to bleed down before rotating cam. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head Off > Page 1434 Valve Spring: Service and Repair Cylinder Head On REMOVAL 1. Remove camshafts. 2. Rotate crankshaft until piston is at Top Dead Center (TDC) on compression. 3. With air hose attached to adapter tool installed in spark plug hole, apply 90 - 120 psi air pressure. 4. Using Special Tool MD998772A with adapter 6779, or equivalents compress valve springs and remove valve locks. 5. Remove valve spring. 6. Remove valve stem seal by using a valve stem seal tool. INSTALLATION 1. Install valve seal/valve spring seat assembly. 2. Install valve spring and retainer. Using Special Tool MD998772A, or equivalent compress valve springs only enough to install locks. Correct alignment of tool is necessary to avoid nicking valve stems (air pressure required), piston at TDC. 3. Remove air hose and install spark plugs. 4. Install camshafts. 5. Install cylinder head cover. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head Off > Page 1435 Valve Spring: Service and Repair Inspection 1. Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested Special Tool C-647, or equivalent. NOTE: As an example, the compression length of the spring to be tested is 33.34 mm (1-5/16 inches). Turn tool table until surface is in line with the 33.34 mm (1-5/16 inch) mark on the threaded stud and the zero mark on the front. Place spring over stud on the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by two. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Discard the springs that do not meet specifications. The Following specifications apply to both intake and exhaust valve springs . - Valve Closed Nominal Force: 58 lbs. @ 38.0 mm (1.50 inch) - Valve Open Nominal Force: 130 lbs. @ 29.25 mm (1.17 inch) 2. Verify springs are not distorted with a steel square and surface plate, check springs from both ends. If the spring is more than 1.5 mm (1/16 inch) out of square, install a new spring. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1436 Valve Spring: Tools and Equipment Valve Spring Compressor MD-998772-A Spring Compressor Adapter 6779 Valve Spring Compressor C-3575-A Valve Spring Tester C-647 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1440 Valve: Description and Operation GENERAL INFORMATION Four valves per cylinder are actuated by roller cam followers which pivot on stationary hydraulic lash adjusters. VALVE SIZES All valves have 6 mm diameter chrome plated valve stems. The valve sizes are 34.8 mm (1.370 inch) diameter intake valves and 30.5 mm (1.20 inch) diameter exhaust valves. COMPONENTS Viton rubber valve stem seals are integral with the spring seats. Valve springs, spring retainers, and locks are conventional. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1441 Valve: Testing and Inspection 1. Clean valves thoroughly and discard burned, warped and cracked valves. 2. Measure valve stems for wear. Measure stem about 60 mm beneath the valve lock grooves. 3. If valve stems are worn more than 0.05 mm (0.002 inch), replace valve. NOTE: Clean all valve guides, valves and valve spring assemblies thoroughly with suitable cleaning solution before reassembling. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation Valve: Service and Repair Removal and Installation REMOVAL 1. With cylinder head removed, compress valve springs using Special Tool MD 998735 or equivalent. 2. Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. 3. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure installation in original location. INSTALLATION 1. Coat valve stems with clean engine oil and insert in cylinder head. 2. Install new valve stem seals on all valves using a valve stem seal tool. The valve stem seals should be pushed firmly and squarely over valve guide. CAUTION: If oversize valves are used, there is only one oversize valve available. The same stem seal is used on both the standard and oversize valve. 3. Install valve springs and retainers. Compress valve springs only enough to install locks, taking care not to misalign the direction of compression. Nicked valve stems may result from misalignment of the valve spring compressor. CAUTION: When depressing the valve spring retainers with valve spring compressor the locks can become dislocated. Check to make sure both locks are in their correct location after removing tool. 4. Check the valve spring installed height B after refacing the valve and seat. Make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 38.75 mm (1.525 inch), install 7.620 mm (0.030 inch) spacer under the valve spring seat to bring spring height back within specification. 5. Install cam followers and camshaft. 6. Checking dry lash. Dry lash is the amount of clearance that exists between the base circle of an installed cam and the rocker arm roller when the adjuster is drained of oil and completely collapsed. NOTE: Specified dry lash is 1.17 mm (0.046 inch) for intake and 1.28 mm (0.050 inch) for exhaust. After performing dry lash check, refill adjuster with oil and allow 10 minutes for adjuster or adjusters to bleed down before rotating cam. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1444 Valve: Service and Repair Refacing Valves and Valve Seats 1. The intake and exhaust valve seats and valve face have a 45 and a 45 1/2 degree angles. 2. Inspect the remaining margin after the valves are refaced. Intake valves with less than 1.2 mm (3/64 inch) margin and Exhaust valves with less than 0.9 mm (1/32 inch) margin should be discarded. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist Drive Belt: Customer Interest Drive Belt - Momentary Loss of Power Steering Assist NO: 07-04-97 GROUP: Accessory Belt DATE: Jun. 6, 1997 SUBJECT: Momentary Loss Of Power Steering Assist When Driving Through Heavy Rain - Deep Puddles MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Momentary loss of power steering assist when driving through heavy rain and/or deep puddles. Loss of power steering is caused by water intrusion into the accessory drive belt area. DIAGNOSIS: Inspect the belt for glazing and/or cracks, if either is found replace the belt following the repair procedure found in the 1997 Neon Service Manual (Publication No. 81-270-7025) Page 7-21. Determine the road conditions the driver of the vehicle was encountering at the time the loss of power assist was experienced. If the driver indicates the loss of power steering assist was during times of heavy rain or deep puddles, perform the Repair Procedure. PARTS REQUIRED: AR(1) 04612247 Belt, Accessory Drive - Power steering and A/C Compressor REPAIR PROCEDURE: This bulletin involves correcting the tension on the power steering accessory drive belt. 1. Loosen the power steering pump locking bolts A and B and pivot bolt C (Illustration) to allow adjustment of belt tension. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist > Page 1454 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square hole "D" on the power steering pivot bracket. Adjust the tension as follows: Belt tension with no belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 100 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). Belt tension with belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 135 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). C. Start the engine and allow the vehicle to idle for 15 minutes to allow the belt to seat. D. Repeat the belt tensioning procedure, set belt tension to 135 lb. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-11-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist Drive Belt: All Technical Service Bulletins Drive Belt - Momentary Loss of Power Steering Assist NO: 07-04-97 GROUP: Accessory Belt DATE: Jun. 6, 1997 SUBJECT: Momentary Loss Of Power Steering Assist When Driving Through Heavy Rain - Deep Puddles MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Momentary loss of power steering assist when driving through heavy rain and/or deep puddles. Loss of power steering is caused by water intrusion into the accessory drive belt area. DIAGNOSIS: Inspect the belt for glazing and/or cracks, if either is found replace the belt following the repair procedure found in the 1997 Neon Service Manual (Publication No. 81-270-7025) Page 7-21. Determine the road conditions the driver of the vehicle was encountering at the time the loss of power assist was experienced. If the driver indicates the loss of power steering assist was during times of heavy rain or deep puddles, perform the Repair Procedure. PARTS REQUIRED: AR(1) 04612247 Belt, Accessory Drive - Power steering and A/C Compressor REPAIR PROCEDURE: This bulletin involves correcting the tension on the power steering accessory drive belt. 1. Loosen the power steering pump locking bolts A and B and pivot bolt C (Illustration) to allow adjustment of belt tension. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist > Page 1460 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square hole "D" on the power steering pivot bracket. Adjust the tension as follows: Belt tension with no belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 100 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). Belt tension with belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 135 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). C. Start the engine and allow the vehicle to idle for 15 minutes to allow the belt to seat. D. Repeat the belt tensioning procedure, set belt tension to 135 lb. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-11-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1461 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1462 Drive Belt: Description and Operation If the engine is equipped with power steering or air conditioning, it will have 2 drive belts. One belt drives the generator, the other drives the Power Steering and Air Conditioning. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1463 Drive Belt: Testing and Inspection Belt replacement under any or all of the following conditions is required, excessive wear, frayed cords or severe glazing. Poly-V-Belt system with back drive pulley may develop minor cracks across the ribbed side (due to reverse bending). These minor cracks are considered normal and acceptable. Cracks parallel are not. NOTE: Do not use any type of belt dressing or restorer on Poly-V-Belt and V-Belt Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Adjustments > A/C Belt Adjustment Drive Belt: Adjustments A/C Belt Adjustment PROPER BELT TENSION Satisfactory performance of the belt driven accessories depends on belt condition and proper belt tension. Refer to Accessory Drive Belt Inspection in this section. There are two belt tensioning methods given in order of preference: Belt tension gauge method. - Torque equivalent method. NOTE: The belt tension gauge method usually requires the vehicle to be raised on a hoist and the splash shield removed. TORQUE EQUIVALENT METHOD Adjustable accessory brackets provided with a 13 mm (1/2 inch) square hole for a torque wrench can use an equivalent torque value for belt adjustment. Equivalent torque values for adjusting these accessory drive belts are specified in above image. BELT TENSION GAUGE METHOD Use belt tensioning Special Tool Kit C-4162 for conventional belts and Poly-V-belts. Adjust the belt tension for a New or Used belt as prescribed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Adjustments > A/C Belt Adjustment > Page 1466 Drive Belt: Adjustments Alternator Belt Adjustment PROPER BELT TENSION Satisfactory performance of the belt driven accessories depends on belt condition and proper belt tension. Refer to Accessory Drive Belt Inspection in this section. There are two belt tensioning methods given in order of preference: Belt tension gauge method. - Torque equivalent method. NOTE: The belt tension gauge method usually requires the vehicle to be raised on a hoist and the splash shield removed. TORQUE EQUIVALENT METHOD Adjustable accessory brackets provided with a 13 mm (1/2 inch) square hole for a torque wrench can use an equivalent torque value for belt adjustment. Equivalent torque values for adjusting these accessory drive belts are specified in above image. BELT TENSION GAUGE METHOD Use belt tensioning Special Tool Kit C-4162 for conventional belts and Poly-V-belts. Adjust the belt tension for a New or Used belt as prescribed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Adjustments > A/C Belt Adjustment > Page 1467 Drive Belt: Adjustments Power Steering Pump Belt Adjustment PROPER BELT TENSION Satisfactory performance of the belt driven accessories depends on belt condition and proper belt tension. Refer to Accessory Drive Belt Inspection in this section. There are two belt tensioning methods given in order of preference: Belt tension gauge method. - Torque equivalent method. NOTE: The belt tension gauge method usually requires the vehicle to be raised on a hoist and the splash shield removed. TORQUE EQUIVALENT METHOD Adjustable accessory brackets provided with a 13 mm (1/2 inch) square hole for a torque wrench can use an equivalent torque value for belt adjustment. Equivalent torque values for adjusting these accessory drive belts are specified in above image. BELT TENSION GAUGE METHOD Use belt tensioning Special Tool Kit C-4162 for conventional belts and Poly-V-belts. Adjust the belt tension for a New or Used belt as prescribed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Belt Drive Belt: Service and Repair A/C Belt 1. Loosen the power steering pump locking bolts A and B and pivot bolt C to remove and install belt and/or adjust belt tension. 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square D hole on the power steering pivot bracket. Adjust tension to specification. 3. Tighten in order, first tighten locking bolt A to 27 Nm (20 ft. lbs.) then, bolt B to 27 Nm (20 ft. lbs.) Then pivot bolt C to 54 Nm (40 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Belt > Page 1470 Drive Belt: Service and Repair Alternator Belt 1. Loosen pivot bolt E then locking nut F and adjusting bolt G to remove and install belt and/or adjust belt tension. 2. Tighten adjusting bolt G. Adjust belt tension to specification. 3. Tighten pivot bolt E to 54 Nm (40 ft. lbs.). Locking nut F to 54 Nm (40 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Belt > Page 1471 Drive Belt: Service and Repair Power Steering Belt 1. Loosen the power steering pump locking bolts A and B and pivot bolt C to remove and install belt and/or adjust belt tension. 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square D hole on the power steering pivot bracket. Adjust tension to specification. 3. Tighten in order, first tighten locking bolt A to 27 Nm (20 ft. lbs.) then, bolt B to 27 Nm (20 ft. lbs.) Then pivot bolt C to 54 Nm (40 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Page 1472 Belt Tension Gauge C-4162 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Power Hop Damper <--> [Engine Torque Strut] > Component Information > Service and Repair Power Hop Damper: Service and Repair NOTE: Power hop damper is used on manual transmission vehicle only. 1. Remove the thru-bolt and nut from the front suspension crossmember. 2. Remove the damper nut and grommets. Remove the damper. 3. Remove the power hop damper bracket, if necessary. 4. Reverse removal procedure for installation. Tighten all bolts and nuts to 54 Nm (40 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Minimum Oil Pressure At Idle Engine Warm ............................................................................................................................................. 78 kPa (11.4 psi) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1481 Engine Oil Pressure: Testing and Inspection 1. Remove oil pressure switch and install gauge assembly C-3292, or equivalent with adaptor. 2. Run engine until thermostat opens. CAUTION: If oil pressure is 0 at idle, Do Not perform the 3000 RPM test in the next step. 3. Oil Pressure: - Curb Idle 25 kPa (4 psi) minimum - 3000 RPM 170 - 550 kPa (25 - 80 psi). 4. If oil pressure is 0 at idle. Shut off engine, check for pressure relief valve stuck open, a clogged oil pick-up screen or a damaged oil pick-up tube O-ring. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications To Pan ................................................................................................................................................. ..................................................... 34 Nm (25 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 4.2L (4.5 Qt) Capacity shown is without filter. When replacing filter, additional oil may be needed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1489 Engine Oil: Fluid Type Specifications Engine Oil API Classification .............................................................................................................................................................. SJ ECII or SJ/CD ECII or Above Above -10°F (-23°C)......................................................................... .......................................................................................................................... 10W-30 Below 100°F (38°C)................................................................................................................................................... .................................................. 5W-30 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1490 Engine Oil: Service Precautions CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1491 Engine Oil: Description and Operation CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result. API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certified or an oil that conforms to the API Service Grade SH or SH/CD. SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. SAE 30 specifies a single viscosity engine oil. Engine oils also have multiple viscosities. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation. ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. They are designated as either ENERGY CONSERVING or ENERGY CONSERVING II. CONTAINER IDENTIFICATION Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans. ENGINE OIL ADDITIVES In some instances, such as infrequent operation, short trip driving, and during break-in after a major overhaul, addition of special materials containing anti-rust and anti-scuff additives are beneficial. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1492 Engine Oil: Testing and Inspection The best time to check engine oil level is after it has sat overnight, or if the engine has been running, allow the engine to be shut off for at least 5 minutes before checking oil level. NOTE: Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Add only when the level is at or below the ADD mark. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1493 Engine Oil: Service and Repair CHANGING ENGINE OIL Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. Refer. to Hoisting and Jacking Recommendations. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 6. Install drain plug in crankcase. 7. Lower vehicle and fill crankcase with specified type and amount of engine oil. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications To Adapter ........................................................................................................................................... ..................................................... 20 Nm (15 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Page 1497 Oil Filter: Description and Operation All engines are equipped with a high quality full flow, disposable type oil filter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Page 1498 Oil Filter: Service and Repair CAUTION: When servicing the oil filter avoid deforming the filter, install tool band strap against the seam at the base of the filter. The seam, joining the can to the base is reinforced by the base plate. 1. Turn counter clockwise to remove. 2. To install, lubricate new filter gasket. Check filter mounting surface. The surface must be smooth, flat and free of debris or old pieces of rubber. Screw filter on until gasket contacts base. Tighten to 21 Nm (15 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications Oil Filter Adapter: Specifications Fastener .............................................................................................................................................. ...................................................... 80 Nm (60 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications > Page 1502 Oil Filter Adapter: Service and Repair Ensure O-ring is in the groove on adapter. Align roll pin into engine block and tighten assembly to 80 Nm (60 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Mounting Bolts ..................................................................................................................................... ............................................... 12 Nm (105 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1506 Oil Pan: Service and Repair REMOVAL 1. Drain engine oil. 2. Remove transmission bending bracket. 3. Remove front engine mount and bracket. 4. Remove transmission inspection cover. 5. If equipped with air conditioning remove oil filter and adapter. 6. Remove oil pan. 7. Clean oil pan and all gasket surfaces. INSTALLATION 1. Apply Mopar Silicone Rubber Adhesive Sealant or equivalent at the oil pump to engine block parting line. 2. Install a new oil pan gasket to pan. 3. Install pan and tighten screws to 12 Nm (105 inch lbs.). 4. Install oil filter and adapter. 5. Install transmission inspection cover. 6. Install front engine mount and bracket. 7. Install transmission bending bracket. 8. Install proper Amount of oil. - With oil filter 4.25 Liters (4.5 Qts.). - Without oil filter 3.8 Liters (4.0 Qts.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation CIRCUIT OPERATION The low oil pressure lamp is used to indicate to the operator that the engine oil pressure has dropped below a predetermined pressure. Power for the lamp is provided on the G5 circuit which also powers the other warning lamps. When the oil pressure is low the normally OPEN oil pressure switch CLOSES completing a path to ground on circuit G6. The oil pressure switch is case grounded to the engine block. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Testing and Inspection > Low Oil Pressure Warning Lamp Test Oil Pressure Warning Lamp/Indicator: Testing and Inspection Low Oil Pressure Warning Lamp Test CAUTION: Disconnect the battery negative cable before servicing the instrument panel or components. When power is required for test purposes, connect battery cable for test only. Disconnect the battery negative cable afier test and before continuing service procedures. The low oil pressure warning lamp will illuminate when the ignition switch is turned to the ON position without engine running. The lamp also illuminates if the engine oil pressure drops below a safe oil pressure level. Oil Pressure Switch To test the system, turn the ignition switch to the ON position. If the lamp fails to light, inspect for a broken or disconnected wire at the oil pressure switch, located at the front of the engine. If the wire at the connector checks good, pull the connector loose from the switch and with a jumper wire, ground the connector to the engine. With the ignition switch turned to the ON position, check the warning lamp. If the lamp still fails to light, inspect for a burned out lamp or disconnected socket in the cluster. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Testing and Inspection > Low Oil Pressure Warning Lamp Test > Page 1512 Oil Pressure Warning Lamp/Indicator: Testing and Inspection Low Oil Warning Circuit The low fuel warning lamp receives its-signal from the fuel gauge drive circuit. Due to production variations, the point where the lamp illuminates, may vary from 1/16 to 3/16 mark on the fuel gauge. There is a built in time delay before the lamp illuminates. This prevents the lamp from going on and off under various road conditions. 1. Verify that the fuel gauge is operating properly 2. Check the low fuel warning lamp assembly. 3. If the lamp still does not function under a low fuel condition replace the printed circuit board. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Minimum Oil Pressure At Idle Engine Warm ............................................................................................................................................. 78 kPa (11.4 psi) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 1517 Engine Oil Pressure: Testing and Inspection 1. Remove oil pressure switch and install gauge assembly C-3292, or equivalent with adaptor. 2. Run engine until thermostat opens. CAUTION: If oil pressure is 0 at idle, Do Not perform the 3000 RPM test in the next step. 3. Oil Pressure: - Curb Idle 25 kPa (4 psi) minimum - 3000 RPM 170 - 550 kPa (25 - 80 psi). 4. If oil pressure is 0 at idle. Shut off engine, check for pressure relief valve stuck open, a clogged oil pick-up screen or a damaged oil pick-up tube O-ring. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Diagrams Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Aluminum Engine - Gasket Surface Preparation Intake Manifold: Technical Service Bulletins Aluminum Engine - Gasket Surface Preparation NO: 09-09-97 GROUP: Engine DATE: Dec. 19, 1997 SUBJECT: Gasket Surface Preparation On Aluminum Engine Components MODELS: 1995 (AA) Acclaim/Spirit 1995 (AJ) Lebaron Convertible 1995 (AS) Caravan/Voyager/Town & Country 1995 - 1998 (FJ) Avenger/Sebring/Talon 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1995 - 1998 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1996 - 1998 (NS) Caravan/Voyager/Town & Country 1995 - 1998 (PL) Neon 1997 (PR) Prowler DISCUSSION: Many aluminum engine components are being received by the material return center with gouges, scratches, and out of flat conditions on the sealing surface. Caution must be exercised when cleaning aluminum engine components. The use of solvents and plastic or wooden scrapers are the only approved methods for removing gasket material. NOTE: DO NOT USE METAL SCRAPERS GRINDING DISCS OR ABRASIVES TO CLEAN ALUMINUM ENGINE COMPONENTS. DAMAGE TO THE SEALING SURFACE WILL OCCUR. Engine components received by the material return center will be evaluated for appropriate gasket removal procedures. Components returned with obvious damage caused by improper gasket removal procedures may be denied for warranty reimbursement. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Mechanical Specifications Intake Manifold: Mechanical Specifications Machining Specifications TORQUE: Mounting Bolts ..................................................................................................................................... ................................................ 23 Nm (17 ft. lbs.) FLATNESS: Standard .............................................................................................................................................. .................................. 0.15 mm (0.006 inch) or less Wear Limit .......................................................... ............................................................................................................................... 0.2 mm (0.008 inch) Intake Manifold Bolts/Nuts 250 in.lb Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Mechanical Specifications > Page 1527 Intake Manifold: Pressure, Vacuum and Temperature Specifications Intake Manifold Vacuum (Min.) ............................................................................................................ .................................................... 60 kPa (18 in-Hg) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1528 Intake Manifold: Description and Operation The intake manifold is a two piece aluminum casting, attached to the cylinder head with ten fasteners. This long branch fan design enhances low and midspeed torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1529 Intake Manifold: Testing and Inspection LEAKAGE DIAGNOSIS An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning. WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR LOOSE CLOTHING. 1. Start the engine. 2. Spray a small stream of water (Spray Bottle) at the suspected leak area. 3. If a change in RPM'S, the area of the suspected leak has been found. 4. Repair as required. GENERAL INSPECTION Check for: Damage and cracks of each section. - Clogged water passages in end crossovers (if equipped). - Check for cylinder head mounting surface distortion using a straightedge and thickness gauge. CLEANING Remove the gasket material from the manifold surfaces. Be careful not to gouge or scratch the sealing surface. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection Intake Manifold: Service and Repair Cleaning and Inspection - Inspect manifold for cracks or distortions. - Check for torn gasket at the mating surface of the manifold. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1532 Intake Manifold: Service and Repair Intake Manifold Replacement Removal WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove fresh air inlet duct. Remove wing nut on intake. 4. Remove the protective cap from the fuel pressure test port on the fuel rail. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1533 5. Place the open end of fuel pressure release hose, tool number C- 4799-1, into an approved gasoline container. Connect the other end of hose to the fuel pressure test port. Fuel pressure will bleed off through the hose into the gasoline container. Fuel gauge C-4799-A contains hose C-4799-1, or equivalents. 6. Disconnect the fuel supply line-connect at fuel tube assembly. 7. Remove clean air inlet duct. CAUTION: Wrap shop towels around hose to catch any gasoline spillage. 8. Disconnect the coolant temperature sensor. 9. Remove fuel rail assembly attaching screws and remove fuel rail assembly from engine. Cover injector holes with suitable covering. CAUTION: Do not set fuel injectors on their tips, damage may occur to the injectors 10. Remove accelerator, kickdown and speed control cables from throttle lever and bracket. 11. Remove throttle body. 12. Disconnect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors. 13. Disconnect vacuum hoses from throttle body. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1534 14. Disconnect Manifold Absolute Pressure/Intake Air Temperature Sensor (TMAP) electrical connector. Disconnect vapor and brake booster hoses. 15. Disconnect knock sensor electrical connector and disconnect wiring harness from tab located OI1 the intake manifold. 16. Disconnect wiring from starter. 17. Remove EGR tube bolts at the valve and at the intake manifold. Remove tube from engine. 18. Remove intake manifold fastener. Remove intake manifold. Installation Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1535 NOTE: Before installing manifold. Clean all mating surfaces. Replace all gaskets, with new. 1. Install intake manifold onto cylinder head and tighten fasteners to 28 Nm (250 inch lbs.) in sequence shown. 2. Remove covering from fuel injector holes and insure the holes are clean. Install fuel rail assembly to intake manifold. Tighten screws to 23 Nm (200 inch lbs.). 3. Connect PCV and brake booster hoses. 4. Inspect quick connect fittings for damage, replace if necessary. Lube tube with clean 30w engine oil, Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to insure it locked into position. 5. Install throttle body. Tighten fastener to 22 Nm (200 inch lbs.). 6. Connect Manifold Absolute Pressure/Intake Air Temperature Sensor (TMAP) wiring connector. 7. Connect knock sensor connector and starter wires. Connect wiring harness to intake manifold tab. 8. Connect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors. 9. Connect vacuum hoses to throttle body. 10. Install accelerator, kickdown and speed control cables to their bracket and connect them to the throttle lever. 11. Loose assemble the EGR tube onto valve and intake manifold finger tight. Tighten tube fasteners at the EGR valve first to 11 Nm (95 inch lbs.) then, tighten the intake manifold side fasteners to 11 Nm (95 inch lbs.). 12. Install clean air duct. 13. Install fresh air duct to air filter housing. Tighten clamp to 3 Nm (25 inch lbs.). 14. Connect negative battery cable. 15. With the Diagnostic Readout Box (DRB) scan tool use Auto Shutdown (ASD) Fuel System Test to pressurize system to check for leaks. CAUTION: When using the ASD Fuel System Test, the ASD relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation CIRCUIT OPERATION The low oil pressure lamp is used to indicate to the operator that the engine oil pressure has dropped below a predetermined pressure. Power for the lamp is provided on the G5 circuit which also powers the other warning lamps. When the oil pressure is low the normally OPEN oil pressure switch CLOSES completing a path to ground on circuit G6. The oil pressure switch is case grounded to the engine block. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Testing and Inspection > Low Oil Pressure Warning Lamp Test Oil Pressure Warning Lamp/Indicator: Testing and Inspection Low Oil Pressure Warning Lamp Test CAUTION: Disconnect the battery negative cable before servicing the instrument panel or components. When power is required for test purposes, connect battery cable for test only. Disconnect the battery negative cable afier test and before continuing service procedures. The low oil pressure warning lamp will illuminate when the ignition switch is turned to the ON position without engine running. The lamp also illuminates if the engine oil pressure drops below a safe oil pressure level. Oil Pressure Switch To test the system, turn the ignition switch to the ON position. If the lamp fails to light, inspect for a broken or disconnected wire at the oil pressure switch, located at the front of the engine. If the wire at the connector checks good, pull the connector loose from the switch and with a jumper wire, ground the connector to the engine. With the ignition switch turned to the ON position, check the warning lamp. If the lamp still fails to light, inspect for a burned out lamp or disconnected socket in the cluster. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Testing and Inspection > Low Oil Pressure Warning Lamp Test > Page 1542 Oil Pressure Warning Lamp/Indicator: Testing and Inspection Low Oil Warning Circuit The low fuel warning lamp receives its-signal from the fuel gauge drive circuit. Due to production variations, the point where the lamp illuminates, may vary from 1/16 to 3/16 mark on the fuel gauge. There is a built in time delay before the lamp illuminates. This prevents the lamp from going on and off under various road conditions. 1. Verify that the fuel gauge is operating properly 2. Check the low fuel warning lamp assembly. 3. If the lamp still does not function under a low fuel condition replace the printed circuit board. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > Front Cam Seal Retainer - New Design Camshaft Oil Seal: Technical Service Bulletins Front Cam Seal Retainer - New Design NUMBER: 09-008-00 GROUP: Engine DATE: Jan. 12, 2001 SUBJECT: Front Cam Seal Retention OVERVIEW: This bulletin involves installation of a new component to assist cam seal retention. MODELS: NOTE: THIS INFORMATION APPLIES TO MODELS EQUIPPED WITH A 1.8 OR 2.0L SOHC ENGINE. DISCUSSION: A new cam seal retainer has been released to retain the front cam seal on 1.8L or 2.0L SOHC engines. Whenever a cam seal is replaced, a retainer should be installed to provide positive retention. PARTS REQUIRED: REPAIR PROCEDURE: 1. Upon engine re-assembly after front cam seal installation, install the retainer p/n 5016733AA using the inner cover fasteners as shown in (Fig. 1) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > Front Cam Seal Retainer - New Design > Page 1548 2. Torque the fasteners to 20 Nm (15 ft. lbs.). 3. Complete the re-assembly following the applicable service manual. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > Page 1549 Camshaft Oil Seal: Service and Repair REMOVAL 1. Remove front timing belt cover and timing belt. CAUTION: Before removing timing belt set crankshaft sprocket 3 notches before Top Dead Center (TDC), this will prevent possible engine damage. 2. Hold camshaft sprocket with Special Tool C-4687 and adaptor C4687-1, or equivalents while removing / installing bolts. 3. Remove camshaft seal using a pry bar. Be careful not to nick or damage the camshaft seal surface or cylinder head seal retaining bore. CAUTION: Do not nick shaft seal surface or seal bore. 4. Shaft seal lip surface must be free of varnish, dirt or nicks. Polish with 400 grit paper if necessary. INSTALLATION Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > Page 1550 1. Install camshaft seal into cylinder head using Special Tool MD 998713, or equivalent until flush with the head. 2. Install camshaft sprockets and tighten attaching bolts to 101 Nm (75 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > Page 1551 Camshaft Seal Installer MD-998713 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Rear Crankshaft Seal <--> [Crankshaft Main Bearing Seal] > Component Information > Description and Operation Rear Crankshaft Seal: Description and Operation Hydrodynamic seals provide end sealing, where the crankshaft exits the block. Anaerobic gasket material is used for parting line sealing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Rear Crankshaft Seal <--> [Crankshaft Main Bearing Seal] > Component Information > Description and Operation > Page 1555 Rear Crankshaft Seal: Testing and Inspection Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak. If the leakage occurs at the crankshaft rear oil seal area: 1. Disconnect the battery. 2. Raise the vehicle. 3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak. If a leak is present in this area remove transmission for further inspection. a. Circular spray pattern generally indicates seal leakage or crankshaft damage. b. Where leakage tends to run straight down, possible causes are a porous block, oil galley cup plug, bedplate to cylinder block mating surfaces and seal bore. See proper repair procedures for these items. 4. If no leaks are detected, pressurized the crankcase. CAUTION: Do not exceed 20.6 kPa (3 psi). 5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal. 6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled. 7. After the oil leak root cause and appropriate corrective action have been identified. Replace rear main seal. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Rear Crankshaft Seal <--> [Crankshaft Main Bearing Seal] > Component Information > Description and Operation > Page 1556 Rear Crankshaft Seal: Service and Repair REMOVAL 1. Insert a 3/16 flat bladed screwdriver between the dust lip and the metal case of the crankshaft seal. Angle the screwdriver through the dust lip against metal case of the seal. Pry out seal. CAUTION: Do not permit the screwdriver blade to contact crankshaft seal surface. Contact of the screwdriver blade against crankshaft edge (chamfer) is permitted. INSTALLATION CAUTION: If burr or scratch is present on the crankshaft edge (chamfer), cleanup with 400 grit sand paper to prevent seal damage during installation of new seal. NOTE: When installing seal, no lube on seal is needed. 1. Place Special Tool 6926-1, or equivalent on crankshaft. This is a pilot tool with a magnetic base. 2. Position seal over pilot tool. Make sure you can read the words THIS SIDE OUT on seal. Pilot tool should remain on crankshaft during installation of seal. Ensure that the lip of the seal is facing towards the crankcase during installation. CAUTION: If the seal is driven into the block past flush, this may cause an oil leak. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Rear Crankshaft Seal <--> [Crankshaft Main Bearing Seal] > Component Information > Description and Operation > Page 1557 3. Drive the seal into the block using Special Tool 6926-2 and handle C-4171, or equivalents until the tool bottoms out against the block. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Rear Crankshaft Seal <--> [Crankshaft Main Bearing Seal] > Component Information > Description and Operation > Page 1558 Rear Crankshaft Seal Guide and Installer 6926-1 and 6926-2 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Multi Layer Steel Head Gasket - Installation Procedures Technical Service Bulletin # 09-08-99 Date: 990917 Multi Layer Steel Head Gasket - Installation Procedures NUMBER: 09-08-99 GROUP: Engine DATE: Sep. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-05-98, DATED NOV. 6, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE PART NUMBER REVISIONS AND MODEL ADDITIONS. SUBJECT: Multi-Layer Steel (MLS) Head Gasket Installation Procedures MODELS: **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - 2000 (JA) Cirrus/Stratus/Breeze 1996 - 2000 (JX) Sebring Convertible 1995-2000 (PL) Neon 1997 - 2000 (GS) Chrysler Voyager (International Market) NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC (NATURALLY ASPIRATED) OR 2.4L ENGINE. DISCUSSION: Multi-Layer Steel (MLS) head gaskets have been developed and released for use on the above models. The MLS gasket was released for production, as a running change, in the 1999 model year for all models except FJ. This new gasket provides superior sealing characteristics, but will require extra care in their installation where a composite gasket was previously in place. The following steps outline the proper installation of this MLS gasket. CAUTION: ALUMINUM ENGINE COMPONENTS ARE SUSCEPTIBLE TO METAL TRANSFER AND SURFACE DAMAGE WHEN OLD GASKET MATERIAL IS REMOVED FROM THEM. USE EXTREME CARE WHEN CLEANING GASKET MATERIAL FROM ALUMINUM COMPONENTS. THE MLS GASKET CANNOT PROPERLY SEAL IF GOUGING OF SURFACES, METAL TRANSFER, OR COMPOSITE GASKET MATERIAL IS LEFT ON THE HEAD OR BLOCK SURFACES. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Multi Layer Steel Head Gasket - Installation Procedures > Page 1563 PARTS REQUIRED: EQUIPMENT REQUIRED: 1 NPN Plastic/Wooden Scraper AR(1) 07528 2" 3M Roloc Bristle Disc White (For Aluminum Surfaces) AR(1) 07525 2" 3M Roloc Bristle Disc Yellow (For Aluminum/Cast Iron/Steel Surfaces) 1 05539 2" 3M Roloc Bristle Disc Arbor 1 NPN Drill Motor POLICY: Information Only. Repair Procedure This bulletin outlines the proper procedures for preparing head/block surfaces for MLS gasket installation. 1. Following service manual procedures, remove the head. 2. Remove as much of the loose composite gasket material with a plastic or wooden scraper. NOTE: PRIOR TO ADDITIONAL CLEANING, INSPECT THE COOLING PASSAGES OF THE HEAD. REPLACEMENT MAY BE NECESSARY IF EXCESSIVE PITTING OR EROSION HAS TAKEN PLACE THAT WILL COMPROMISE THE SEALING SURFACES AROUND THE COOLING PASSAGES. 3. Cover coolant and oil passages to the best of your ability and apply solvent or a commercially available gasket cleaner to the head/block surfaces. Allow the solvent to soften the remaining composite gasket material. 4. Using a plastic or wooden scraper, scrape the composite gasket residue from the surfaces. If necessary, apply additional solvent or gasket remover to ease removal. 5. If additional cleaning is needed, use a drill motor and 3M Roloc bristle disc p/n 07528 (white) to carefully remove the remaining gasket material from the head and block surfaces. NOTE: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Multi Layer Steel Head Gasket - Installation Procedures > Page 1564 IF DIFFICULT TO REMOVE RESIDUE IS LEFT, THE YELLOW ROLOC BRISTLE DISK 3M P/N 07525 CAN BE USED. USE EXTREME CARE WHEN POWER CLEANING ALUMINUM SURFACES TO PREVENT METAL TRANSFER. 6. Inspect the sealing surfaces for any remaining composite gasket residue. Carefully remove any remaining material. 7. The head and block must be checked for flatness. Follow service manual procedures/specifications where applicable. 8. Spray both sides of the MLS gasket with a coat of MOPAR spray gasket sealant p/n 04318035. 9. Re-assemble the engine as outlined in the appropriate service manual. Pay particular attention to head bolt torque and torqueing procedures. All head bolts should be oiled prior to assembly. NOTE: THE 2.0L DOHC TORQUE AND TORQUING PROCEDURE HAS CHANGED WITH THE INSTALLATION OF A MLS GASKET. USE THE FOLLOWING PROCEDURES FOR THE 2.0L DOHC ONLY. 2.OL DOHC TORQUE PROCEDURE WITH MLS GASKET INSTALLATION NOTE: THE 4 SHORT BOLTS ARE PLACED IN THE CORNERS. A. Torque all center bolts to 34 Nm (25 Ft Lbs), Torque the 4 corner bolts to 27 Nm (20 Ft Lbs) see Fig 1 for torque sequence. B. Torque all center bolts to 68 Nm (50 Ft Lbs), Torque the 4 corner bolts to 47 Nm (35 Ft Lbs) see Fig 1 for torque sequence. C. Re-torque all center bolts to 68 Nm (50 Ft Lbs), Re-torque the 4 corner bolts to 47 Nm (35 Ft Lbs) see Fig 1 for torque sequence. D. Tighten all bolts in the specified sequence (Fig 1) an additional 90° (1/4 turn). 10. Make sure the cam sensor seal is replaced on all engine applications. NOTE: A NEW CAM SENSOR SEAL MUST BE INSTALLED DURING THE HEAD GASKET REPLACEMENT PROCEDURE. OIL SEEPAGE FROM THIS SEAL CAN BE MISINTERPRETED AS A HEAD GASKET LEAK. 11. Replace the engine oil and filter after performing these procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Multi Layer Steel Head Gasket - Installation Procedures > Page 1565 Cylinder Head Gasket: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Description and Operation Front Crankshaft Seal: Description and Operation Hydrodynamic seals provide end sealing, where the crankshaft exits the block. Anaerobic gasket material is used for parting line sealing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Description and Operation > Page 1569 Front Crankshaft Seal: Service and Repair CAUTION: Do Not Rotate the camshaft or crankshaft when timing belt is removed damage to the engine may occur. REMOVAL 1. Using Special Tool 1026 and Insert 6827-A, or equivalents remove crankshaft damper. 2. Remove outer timing belt cover and timing belt. 3. Remove crankshaft sprocket using Special Tool 6793 and insert C- 4685-C2, or equivalents. CAUTION: Do not nick shaft seal surface or seal bore. 4. Using Tool 6771, or equivalent to remove front crankshaft oil seal. Do not damage the seal contact area on the crankshaft. INSTALLATION Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Description and Operation > Page 1570 1. Install new seal by using Tool 6780-1, or equivalent. 2. Place seal into opening with seal spring towards the inside of engine. Install seal until flush with cover. 3. Install crankshaft sprocket. Using Special Tool 6792, or equivalent. NOTE: Make sure the word "front" on the sprocket is facing you. 4. Install timing belt and covers. 5. Install crankshaft damper. Use thrust bearing/washer and 12M-1.75 x 150 mm bolt from Special Tool 6792, or equivalent. Install crankshaft damper bolt and tighten to 142 Nm (105 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Description and Operation > Page 1571 Front Crankshaft Seal: Tools and Equipment Front Crankshaft Seal Remover 6771 Front Crankshaft Seal Installer 6780 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Description and Operation Valve Guide Seal: Description and Operation Viton rubber valve stem seals are integral with spring seats. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Cylinder Head Off Valve Guide Seal: Service and Repair Cylinder Head Off REMOVAL 1. With cylinder head removed, compress valve springs using Special Tool MD 998735 or equivalent. 2. Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. 3. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure installation in original location. INSTALLATION 1. Coat valve stems with clean engine oil and insert in cylinder head. 2. Install new valve stem seals on all valves using a valve stem seal tool. The valve stem seals should be pushed firmly and squarely over valve guide. CAUTION: If oversize valves are used, there is only one oversize valve available. The same stem seal is used on both the standard and oversize valve. 3. Install valve springs and retainers. Compress valve springs only enough to install locks, taking care not to misalign the direction of compression. Nicked valve stems may result from misalignment of the valve spring compressor. CAUTION: When depressing the valve spring retainers with valve spring compressor the locks can become dislocated. Check to make sure both locks are in their correct location after removing tool. 4. Check the valve spring installed height B after refacing the valve and seat. Make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 38.75 mm (1.525 inch), install 7.620 mm (0.030 inch) spacer under the valve spring seat to bring spring height back within specification. 5. Install cam followers and camshaft. 6. Checking dry lash. Dry lash is the amount of clearance that exists between the base circle of an installed cam and the rocker arm roller when the adjuster is drained of oil and completely collapsed. NOTE: Specified dry lash is 1.17 mm (0.046 inch) for intake and 1.28 mm (0.050 inch) for exhaust. After performing dry lash check, refill adjuster with oil and allow 10 minutes for adjuster or adjusters to bleed down before rotating cam. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Cylinder Head Off > Page 1577 Valve Guide Seal: Service and Repair Cylinder Head On REMOVAL 1. Remove camshafts. 2. Rotate crankshaft until piston is at Top Dead Center (TDC) on compression. 3. With air hose attached to adapter tool installed in spark plug hole, apply 90 - 120 psi air pressure. 4. Using Special Tool MD998772A with adapter 6779, or equivalents compress valve springs and remove valve locks. 5. Remove valve spring. 6. Remove valve stem seal by using a valve stem seal tool. INSTALLATION 1. Install valve seal/valve spring seat assembly. 2. Install valve spring and retainer. Using Special Tool MD998772A, or equivalent compress valve springs only enough to install locks. Correct alignment of tool is necessary to avoid nicking valve stems (air pressure required), piston at TDC. 3. Remove air hose and install spark plugs. 4. Install camshafts. 5. Install cylinder head cover. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Sprocket Bolt ....................................................................................................................................... .................................................. 115 Nm (85 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Page 1582 Camshaft Gear/Sprocket: Tools and Equipment Camshaft Sprocket Remover/Installer C-4687 Camshaft Sprocket Remover/Installer Adapter C-4687-1 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Description and Operation Crankshaft Gear/Sprocket: Description and Operation GENERAL INFORMATION A sintered iron timing belt sprocket is mounted on the crankshaft nose. This sprocket transmits crankshaft movement, via timing belt to the camshaft sprocket providing timed valve actuation. BOLT ACCESS PLUG An Access plug is located in the right inner fender shield. Remove the plug and insert the proper size socket, extension and ratchet, when crankshaft rotation is necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Description and Operation > Page 1586 Crankshaft Gear/Sprocket: Tools and Equipment Crankshaft Sprocket Remover 6793 Crankshaft Sprocket Installer 6792 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications Timing Belt: Specifications Timing Belt Service Replacement Interval Information Not Supplied by the Manufacturer. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation Timing Belt: Service and Repair Timing Belt Removal and Installation CAUTION: Camshaft or crankshaft should not be rotate after timing belt is removed. Damage to valve components may occur. Always align timing marks before removing timing belt. REMOVAL 1. Remove crankshaft damper bolt. 2. Remove engine mount bracket and timing belt cover fasteners, remove cover. 3. Align camshaft timing marks. Loosen timing belt tensioner fasteners and remove timing belt. CAUTION: Do not loosen, tighten, or remove the tensioner pivot bolt. INSTALLATION 1. When tensioner is removed from the engine it is necessary to compress the plunger into the tensioner body. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1592 2. Place the tensioner into a vise and slowly compress the plunger. CAUTION: Index the tensioner in the vise the same way it is installed on the engine. This is to ensure proper pin orientation when tensioner is installed on the engine. 3. When plunger is compressed into the tensioner body install a pin through the body and plunger to retain plunger in place until tensioner is installed. 4. Set crankshaft sprocket to Top Dead Center (TDC) by aligning the sprocket with the arrow on the oil pump housing, then back off to 3 notches before TDC. 5. Set camshafts timing marks together by aligning notches on sprockets. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1593 6. Rotate crankshaft 1/2 tooth counterclockwise from TDC. 7. Install timing belt in this direction. Starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprockets and then around the tensioner pulley. 8. Move crankshaft sprocket to TDC to take up belt slack. Install tensioner to Clock but do not tighten fasteners. 9. Using a torque wrench on the tensioner pulley apply 28 Nm (250 inch lbs.) of torque to tensioner. 10. With torque being applied to the tensioner pulley move the tensioner up against the tensioner pulley bracket and tighten fasteners to 31 Nm (275 inch lbs.). 11. Pull tensioner plunger pin. Pretension is correct when pin can be removed and installed freely. 12. Rotate crankshaft 2 revolutions and check the alignment of the timing marks. 13. Install front half of timing cover. 14. Install engine mount bracket. 15. Install right engine mount. 16. Remove jack from under engine. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1594 17. Install crankshaft damper using M12 1.75 x 150 mm bolt, washer, thrust bearing and nut from Special Tool 6792. Install crankshaft damper bolt and tighten to 142 Nm (105 ft. lbs.). 18. Install accessory drive belts. 19. Raise vehicle on hoist and install right inner splash shield. 20. After timing belt has been replaced, use a Diagnostic Readout Box (DRB), or equivalent select adjustments and then relearn CMP/CKP, to relearn camshaft and crankshaft timing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1595 Timing Belt: Service and Repair Camshaft and Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1596 Timing Belt: Service and Repair Camshaft Sprockets and Timing Procedure With Cover Installed 1. Remove number one spark plug. 2. Using a dial indicator, set number one cylinder to Top Dead Center (TDC) on the compression stroke. 3. Remove the timing belt access cover from the engine. 4. Check the timing marks on the camshaft sprockets, they should align with each other. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Specifications Timing Belt Tensioner: Specifications Assembly Mechanical Bolts ................................................................................................................. ............................................... 28 Nm (250 inch lbs.) Assembly Hydraulic Bolt ................................... ....................................................................................................................................... 31 Nm (23 ft. lbs.) Tensioner-Hydraulic Bolts ............................................................................................................ ............................................................ 31 Nm (23 ft. lbs.) Tensioner .................................................. ........................................................................................................................................... 28 Nm (250 inch lbs.) Backing Plate Bolts ...................................................................................................... ............................................................................ 41 Nm (30 ft. lbs.) Pulley Bolt ................................. .............................................................................................................................................................. . 68 Nm (50 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair Timing Cover: Service and Repair CAUTION: Camshaft or crankshaft should not be rotated after timing belt is removed. Damage to valve components may occur. Always align timing marks before removing timing belt. REMOVAL 1. Remove accessory drive belts. 2. Raise vehicle on a hoist and remove right inner splash shield. 3. Remove crankshaft damper bolt. Remove damper using Special Tool 1026 and Insert 6827-A or equivalent. 4. Lower vehicle and place a jack under engine 5. Remove right engine mount. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Page 1603 6. Remove right engine mount bracket. 7. Remove timing belt cover fasteners, remove cover. INSTALLATION 1. Install front timing cover. 2. Install engine mount bracket. 3. Install Right engine mount. 4. Remove jack from under engine. 5. Install crankshaft vibration damper 6. Install accessory drive belts. 7. Raise vehicle on hoist and install right inner splash shield. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Typical -- SOHC Shown Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle Odometer <= 1,000 Miles ................................................................................ ............................................................................................. 550 - 1,300 rpm Odometer >= 1,000 Miles .................................................................................................................................................... ......................... 600 - 1,300 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1612 Idle Speed: Testing and Inspection Fig. 31 PCV Vacuum Nipple 1. Turn ignition key off. 2. Disconnect the PCV valve hose from the intake manifold nipple (Fig. 31). Cap the PCV vacuum nipple. Fig. 32 Purge Hose 3. Disconnect purge hose from the nipple on the throttle body (Fig. 32). Fig. 33 Orifice 6457 Attached To Purge Nipple 4. Use a piece of hose to attach Air Metering Orifice 6457 (0.125 in. orifice) or equivalent, to the purge nipple on the throttle body (Fig. 33). 5. Ensure that all accessories are off. 6. Connect the DRB or equivalent scan tool to the data link connector inside the passenger compartment. 7. Run engine in Park or Neutral until the cooling fan has cycled on and off at least once (180°F). 8. Using the DRB or equivalent scan tool, access Minimum Airflow Idle Speed. 9. The following will then occur: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1613 - Idle air control motor will fully close - Idle spark advance will become fixed - PCM will go open loop enriched - DRB or equivalent scan tool displays engine RPM 10. If idle RPM is within the range shown below, throttle body minimum airflow is set correctly. Odometer Reading Idle RPM Below 1,000 Miles 550 - 1,300 RPM Above 1,000 Miles 600 - 1,300 RPM 11. If idle RPM is above specifications, use the DRB or equivalent scan tool to check idle air control motor operation. If idle air control motor is OK, replace throttle body. If idle air flow is below specification, shut off the engine and clean the throttle body as follows: a. Remove the throttle body from engine. WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves, do not let Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash thoroughly after using cleaner. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when is closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 14. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 12. Shut off engine. 13. Remove Air Metering Orifice 6457 or equivalent. Install purge hose. 14. Remove cap from PCV valve. Connect hose to PCV valve. 15. Remove DRB or equivalent scan tool. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Fig. 104 Air Intake Duct Fig. 105 Removal/Installation of Air Inlet Duct NOTE: Neon vehicles do not use a heated air inlet system. The PCM adjusts fuel injector pulse width and ignition timing to compensate for different ambient temperatures. NOTE: The air cleaner attaches to a bracket on the rear of the cylinder head. An ambient air duct supplies underhood air for the engine. REMOVAL 1. Remove air intake tube (Fig. 104) from air cleaner and intake manifold (Fig. 105). Fig. 106 Removal/Installation Air Cleaner Front Housing and Element 2. Tighten clasps on top of air cleaner housing. Rotate front of housing forward then lift front away from air cleaner housing (Fig 106). 3. Remove air cleaner element from front housing (Fig. 106). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1618 INSTALLATION 1. Install air cleaner element into front housing. 2. Rotate front of housing forward then lower into place and locate tabs in slots. - Fasten clasps on top of air cleaner housing. - Install air intake duct at air cleaner and intake manifold. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1623 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 12 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) 6. Replace Pressure test port cap when finished releasing pressure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Cable Routing and Firing Order Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Cable Routing and Firing Order Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum Cables #1 & #4 3,050 Ohms 4,250 Ohms Cables #2 & #3 2,300 Ohms 3,300 Ohms Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1634 Ignition Cable: Description and Operation NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Plastic clips in various locations protect the cables from damage. When the cables are replaced the clips must be used to prevent damage to the cables. The #1 cable must be routed under the PCV hose and clipped to the #2 cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Ignition Cable: Initial Inspection and Diagnostic Overview Fig. 3 Spark Plug Cables NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Be sure that the plastic clip on PCV hose is positioned so that cable clip is beneath hose, and that #1 cable is snapped into this clip to protect it from metal PCV clamp. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1637 Ignition Cable: Component Tests and General Diagnostics Testing For Open Circuits, High Resistance and Loose Terminals Use an ohmmeter to check cables for opens, loose terminals or high resistance as follows: 1. Remove cable from spark plug. 2. Remove cable from the coil tower. 3. Connect the ohmmeter between the spark plug end terminal and the coil end terminal. - Make sure ohmmeter probes are in good contact. - Resistance should be within tolerance shown in the cable resistance chart. - If resistance is not within tolerance, replace cable assembly. Test all spark plug cables in the same manner. - If no problems are found, SEE Ignition System/System Diagnosis/Testing For Spark At Coil. SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum Cables #1 & #4 3,050 Ohms 4,250 Ohms Cables #2 & #3 2,300 Ohms 3,300 Ohms Testing For Punctures and Cracks When testing cables for punctures and cracks with an oscilloscope and an inductive voltage probe, follow the instructions of the equipment manufacturers. CAUTION: Do not leave any one spark plug cable disconnected for more than 30 seconds during test or possible heat damage to catalytic converter will occur. If an oscilloscope and inductive probe are not available, cables can be tested as follows: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. WARNING: The ignition system generates approximately 40,000 volts. Personal injury could result from contact with this system. 2. With the engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). - If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. - Replace cracked, leaking or faulty cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning Ignition Cable: Service and Repair Cleaning Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning > Page 1640 Ignition Cable: Service and Repair Replacement Fig. 3 Spark Plug Cables NOTE: The cables insulate the spark plugs and cover the top of the spark plug tube (Fig. 3). CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. REMOVAL 1. Remove spark plug cable from coil first. Lightly grasp the top of the cable. 2. Rotate the insulator 1/2 turn and pull straight up in a steady motion. 3. To replace the cables, disconnect the cable from the ignition coil. INSTALLATION Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube.Then connect the other end to coil pack. Be sure that the plastic clip on PCV hose is positioned so that cable clip is beneath hose, and that #1 cable is snapped into this clip to protect it from metal PCV clamp. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... .......................................................... (0.033-0.038 in) Torque ............................................................ ............................................................................................................................................... 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1644 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ....................................................................... RC9YC Thread Size .................................................... ................................................................................................................................................. (14mm) 3/4 in. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1645 Spark Plug: Description and Operation Resistor spark plugs are used in this engine. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for spark plug diagnosis. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1648 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear - Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1649 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1650 Spark Plug: Testing and Inspection Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1651 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear - Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1652 clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Heavy Colored Deposits DESCRIPTION: Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on the side facing the intake valve. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap, and reinstall .............................................................................................................................................................. .................................................................................... Normal Operating Conditions NORMAL OPERATING CONDITIONS Normal Operation And Cold(Carbon) Fouling The few deposits present will be probably light tan or slightly gray in color with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 1600 km (1000 miles) of operation for non Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1653 platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, have the electrodes filed and regapped, and then reinstalled. CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum spark plugs. This would damage the platinum pads which would shorten spark plug life. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit. The rust color deposits can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Oil or Ash Encrusted OIL OR ASH ENCRUSTED Oil Or Ash Encrusted If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of spark plugs. Ash encrusted spark plugs can be cleaned and reused. Premature Electrode Wear - Preignition Damage PREIGNITION DAMAGE Preignition Damage Excessive combustion chamber temperature can cause preignition damage. First, the center electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Other possible causes include ignition timing over-advanced and incorrect spark plug heat range. Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1654 center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Determine if the spark plugs are the correct type, as specified on the VECI label, or if other operating conditions are causing engine overheating. Red, Brown, Yellow or White Deposits - Fuel Additives SCAVENGER DEPOSITS Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed using standard procedures. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and reused. Shiny Yellow Glaze COMBUSTION DEPOSITS A shiny yellow glaze coating on the spark plug insulator is evidence of metallic by-products of fuel combustion, caused by chemical additives in certain fuels. Avoid sudden acceleration with wide open throttle after long periods of low speed driving. Spark plugs with combustion deposits can be cleaned and reused. Spark Plug Inspection - Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance Schedules. - Spark plugs that have low mileage may be cleaned and reused if not otherwise defective -- SEE Spark Plug Condition. After cleaning, file the center electrode flat with a small point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The spark plug gap is 0.033 to0.038 in. - Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Wet Oily Deposits FUEL FOULING A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air and reinstall them in the engine. White or Gray - Burned or Blistered Insulator SPARK PLUG OVERHEATING Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1655 Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in. per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug overheating. Also check for lean air-fuel mixture. Check the torque value of the plugs to ensure good plug-engine seat contact. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1656 Spark Plug: Adjustments Setting Spark Plug Electrode Gap Fig.2 Setting Spark Plug Electrode Gap Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground -- center electrode. Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap .............................................................................................................................................. ............................................. 0.033 to 0.038 in Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1657 Spark Plug: Service and Repair CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. CAUTION: Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion. SPARK PLUG REMOVAL 1. Remove the spark plug using a quality socket with a rubber or foam insert. 2. Inspect the spark plug condition. SPARK PLUG CLEANING Spark plugs that have low mileage may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. SPARK PLUG INSTALLATION 1. To avoid cross threading, start the spark plug into the cylinder head by hand. 2. Tighten spark plugs to 28 Nm (20 ft lb) torque. 3. Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube. 4. Connect coil. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications COMPRESSION PRESSURE (at 250 - 400 RPM): Standard .............................................................................................................................................. ............................ 1172 - 1551 kPa (170 - 225 psi) Minimum ............................................................. ................................................................................................................................... 689 kPa (100 psi) COMPRESSION PRESSURE DIFFERENCE OF ALL CYLINDER: Maximum ............................................................................................................................................. ....................................................................... 25% VACUUM: Manifold ............................................................................................................................................... .......................................... 60 kPa (18 inches Hg) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1661 Compression Check: Testing and Inspection PROCEDURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire (Conventional Ignition System). For Direct Ignition System (DIS) disconnect the coil connector. 5 . Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adaptor into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is reached on gage. Record this pressure as #1 cylinder pressure. 7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 9. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. 11. Clean or replace spark plugs as necessary and adjust gap. Tighten to specifications. 12. Test resistance of spark plug cables. Perform secondary circuit inspection. 13. Test coil output voltage, primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at idle and different RPM ranges. 15. The air filter elements should be replaced as specified. 16. Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt drives. 18. Road test vehicle as a final test. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates this engine is equipped with hydraulic lifters or lash adjusters and therefore does not require adjustment. See "Rocker Arm: Service and Repair" for further information. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Mounting Bolts ..................................................................................................................................... ............................................... 12 Nm (105 inch lbs.) Inlet Tube To Engine Block .............................. .................................................................................................................................. 12 Nm (105 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1668 Water Pump: Description and Operation GENERAL INFORMATION The water has a diecast aluminum body and housing with a stamped steel impeller. The water pump bolts directly to the block. Cylinder block to water pump sealing is provided by a rubber O-ring. The water pump is driven by the timing belt. The water pump is the heart of the cooling system , pumping the coolant through the engine block, cylinder head, heater core, and radiator. NOTE: The water pump on all models can be replaced without discharging the air conditioning system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1669 Water Pump: Testing and Inspection OPERATIONAL TEST A quick flow test to tell whether or not the pump is working is to see if the heater warms properly. A defective pump will not be able to circulate heated coolant through the long heater hose. Another flow test to help determine pump operation, remove radiator cap. CAUTION: DO NOT remove radiator cap if the cooling system is hot or under pressure. FLOW TEST 1. Remove radiator cap. 2. Remove a small amount of coolant from the system, start the engine and warm up until thermostat opens. With the thermostat open and coolant level low you will see if the water pump is pumping coolant through the system. REASONS FOR REPLACEMENT Replace water pump body assembly if it has any of these defects: Cracks or damage on the body. - Coolant leaks from the shaft seal, evident by coolant traces on the pump body. - Loose or rough turning bearing. - Impeller rubs either the pump body or the engine block. - Impeller loose or damaged. - Sprocket or sprocket flange loose or damaged. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1670 Water Pump: Service and Repair REMOVAL 1. Raise vehicle on a hoist. Remove right inner splash shield. 2. Remove accessory drive belts and power steering pump. 3. Drain cooling system. 4. Support engine from the bottom and remove right engine mount. 5. Remove power steering pump bracket bolts and set pump and bracket assembly aside. Power steering lines do not need to be disconnected. 6. Remove right engine mount bracket. 7. Remove timing belt. 8. Remove inner timing belt cover. 9. Remove water pump attaching screws to engine. INSTALLATION 1. Install O-ring in water pump body O-ring groove. Use small dabs of Mopar Silicone Rubber Adhesive Sealant, or equivalent around the water pump body to secure O-ring in place during installation. CAUTION: Make sure O-ring is properly seated in water pump groove before tightening screws. An improperly located O-ring may cause damage to the O-ring and cause a coolant leak. 2. Assemble pump body to block and tighten screws to 12 Nm (105 inch lbs). Pressurize cooling system to 15 psi with pressure tester and check water pump shaft seal and O-ring for leaks. 3. Rotate pump by hand to check for freedom of movement. 4. Install inner timing belt cover. 5. Install timing belt. 6. Install right engine mount bracket and engine mount. 7. Fill cooling system. 8. Install power steering pump and accessory drive belts. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations Coolant: Technical Service Bulletins Engine - Coolant Recommendations NO: 07-03-97 GROUP: Cooling DATE: May 9, 1997 SUBJECT: Engine Coolant Usage THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-05-93 DATED NOV. 26, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1993 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-94000). THE COMPLETE BULLETIN IS REVISED. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1997 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger/ Power Ram/Power Ram Cab & Chassis 1989 - 1993 (AG) Daytona 1989 (AH) Lancer/LeBaron GTS 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1997 (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1997 (BR) Ram Truck 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1989 - 1992 (MJ) Comanche 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1997 (PR) Prowler 1992 - 1997 (SR) Viper/Viper Coupe 1997 (TJ) Wrangler 1989 - 1997 (XJ) Cherokee 1989 - 1995 (YJ) Wrangler 1993 - 1997 (ZJ) Grand Cherokee DISCUSSION: Some owners have expressed interest in using engine coolants made with propylene glycol instead of ethylene glycol due to its lower toxicity and resultant reduced hazards to children and animals. Based on recent test data, most owners should not experience significant effects on cooling system performance when using propylene glycol based coolant. The use of national brand propylene glycol based engine coolant that meets the same Chrysler ethylene glycol specification of MS-7170 (or equivalent ASTM D5216) is acceptable for Chrysler built vehicles. NOTE: ANTIFREEZE SOLD FOR PROTECTING PLUMBING ETC. (RV ANTIFREEZE) IS NOT A SUITABLE ENGINE COOLANT. However, owners should be discouraged from changing their engine coolant prior to the regularly scheduled maintenance period. Prematurely changing engine coolant unnecessarily adds to the risk of environmental exposure. Sufficient freeze protection for the region should be maintained. However, do not use more than a 55% solution (-35 F, -37 C). Use the chart that accompanies the propylene glycol coolant, since a higher concentration is required to obtain the same freeze points as ethylene glycol coolant. If the temperatures for your region fall below this, use ethylene glycol coolant. Under severe driving conditions (towing a trailer in hot weather etc.) there may be a slight loss in cooling performance. If this is noticed, the system should be changed back to ethylene glycol coolant. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations > Page 1676 The two types of coolant should not be mixed. The standard testers for measuring freeze protection will not provide an accurate reading when this occurs. If the cooling system is changed to propylene glycol, all the ethylene glycol coolant should be removed using an approved cooling system flush procedure. The freeze protection of propylene glycol cannot be measured with a standard cooling system hydrometer. A refractometer or hydrometer calibrated for propylene glycol is the preferred test tool. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System Capacity .................................................................................................................... ............................................................. 7.0L (7.4 qts) NOTE: Capacity includes heater and coolant reserve system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1679 Coolant: Fluid Type Specifications GENERAL INFORMATION Performance is measurable. For heat transfer pure water absorbs 1 btu for each degree of temperature rise for each pound of water. This formula is altered when necessary additives to control boiling, freezing, and corrosion are added as follows: Pure Water (1 btu) boils at 100°C (212°F) and freezes at 0°C (32°F). - 100 Percent ethylene glycol (0.7 btu) can cause an engine to run hot, cause detonation, and will freeze at -22°C (-8°F). - 50/50 Ethylene Glycol and Distilled Water (0.82 btu) is the recommended combination that provides a freeze point of -37°C (-35°F). The radiator, water pump, engine water jacket, radiator pressure cap, thermostat, temperature gauge, coolant sensor and heater are all designed for 50/50 ethylene glycol. - Where required, a 56 percent glycol and 44 percent water mixture will provide a freeze point of -46°C ( -50°F ). NOTE: Richer mixtures cannot be measured with field equipment and can lead to problems associated with 100 percent glycol. If there is doubt that the coolant mixture is to rich for field equipment to measure, put a sample in a clean container. Add exactly the same amount of water and retest. If the coolant in the vehicle is 100% antifreeze, the diluted sample will read 50%. If the coolant in the vehicle was 70% antifreeze and 30% water, the diluted sample will read as 35%, etc. SELECTION AND ADDITIVES The use of aluminum cylinder heads, intake manifolds, and water pumps requires special corrosion protection. Mopar Antifreeze or their equivalent are recommended for best engine cooling without corrosion. When mixed only to a freeze point of -37°C (-35°F) to -59°C (-50°F). If it looses color or becomes contaminated, drain, flush, and replace with fresh properly mixed solution. CAUTION: Do not use well water, or suspected water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > General Information Coolant: Description and Operation General Information GENERAL INFORMATION The cooling system is designed around the coolant. PICKING UP HEAT The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves. GIVING OFF HEAT Then carry this heat to the radiator where the tube/fin assemblies of these components can give off the heat to the air. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > General Information > Page 1682 Coolant: Description and Operation Coolant Performance GENERAL INFORMATION Performance is measurable. For heat transfer pure water absorbs 1 btu for each degree of temperature rise for each pound of water. This formula is altered when necessary additives to control boiling, freezing, and corrosion are added as follows: Pure Water (1 btu) boils at 100°C (212°F) and freezes at 0°C (32°F). - 100 Percent ethylene glycol (0.7 btu) can cause an engine to run hot, cause detonation, and will freeze at -22°C (-8°F). - 50/50 Ethylene Glycol and Distilled Water (0.82 btu) is the recommended combination that provides a freeze point of -37°C (-35°F). The radiator, water pump, engine water jacket, radiator pressure cap, thermostat, temperature gauge, coolant sensor and heater are all designed for 50/50 ethylene glycol. - Where required, a 56 percent glycol and 44 percent water mixture will provide a freeze point of -46°C ( -50°F ). NOTE: Richer mixtures cannot be measured with field equipment and can lead to problems associated with 100 percent glycol. If there is doubt that the coolant mixture is to rich for field equipment to measure, put a sample in a clean container. Add exactly the same amount of water and retest. If the coolant in the vehicle is 100% antifreeze, the diluted sample will read 50%. If the coolant in the vehicle was 70% antifreeze and 30% water, the diluted sample will read as 35%, etc. SELECTION AND ADDITIVES The use of aluminum cylinder heads, intake manifolds, and water pumps requires special corrosion protection. Mopar Antifreeze or their equivalent are recommended for best engine cooling without corrosion. When mixed only to a freeze point of -37°C (-35°F) to -59°C (-50°F). If it looses color or becomes contaminated, drain, flush, and replace with fresh properly mixed solution. CAUTION: Do not use well water, or suspected water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Page 1683 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump Inlet Tube <--> [Coolant Line/Hose] > Component Information > Service and Repair Water Pump Inlet Tube: Service and Repair The inlet tube connects the water pump to the radiator and heater core. This tube is sealed by an O-ring and held in place by fasteners to the block. REMOVAL CAUTION: Do not use any sharp tools to remove hoses from inlet tube. This may cause the tube to leak. 1. Drain cooling system. 2. Remove upper radiator hose to access the hose connections at the inlet tube. Figure 19 3. Remove lower radiator hose and heater hose from the inlet tube. 4. Remove the two fasteners that hold the inlet tube to the block and one fastener that holds the intake manifold to inlet tube. Figure 20 5. Rotate tube while removing the tube from the engine block. INSTALLATION 1. Inspect the O-ring for damage before installing the tube into the cylinder block. Replace O-ring as necessary. 2. Lubricate O-ring with coolant and install inlet tube into the cylinder block opening. 3. Install two fasteners to the engine block and the one fastener to the intake manifold. Tighten fasteners to 12 Nm (105 inch lbs.). 4. Connect lower radiator hose and heater hose to inlet tube. 5. Install upper radiator hose. 6. Fill cooling system. 7. Pressure system to 104 kPa (15 psi) to check for leaks. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Specifications Radiator Cooling Fan Motor: Specifications Fan Motor to Shroud Retaining Screws (A/C Equipped) 3.8 Nm 34 In Lbs Fan Motor to Shroud Retaining Screws (non A/C Equipped) 2.3 Nm 20 In Lbs Fan Module (Shroud) to Radiator Fasteners 7.3 Nm 65 In Lbs Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1693 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1694 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1695 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1696 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1697 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1698 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1699 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1700 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1701 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1702 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1703 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1704 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1705 Radiator Cooling Fan Motor: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1706 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1707 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1708 Radiator Cooling Fan Motor: Electrical Diagrams Dual Cooling Fans A/C & Heater System -- Sheet 8w-42-4 Chrysler Does not provide a wiring diagram for dual fans on 95-98 model year Neons. This diagram is for the 99 model year and is presented for reference only. Single Cooling Fan Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1709 A/C And Heat Part 1 of 4 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1710 A/C And Heat Part 2 Of 4 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1711 A/C And Heat Part 3 Of 4 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1712 A/C And Heat Part 4 Of 4 The OE does not show a wiring diagram showing the dual fan option specifically until 1999 but the dual fan option is mentioned. Additionally, the Radiator Fan Control is shown as a portion of the A/C circuit and as a portion of the PCM circuit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1713 Cooling Fan Modules Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Description and Operation > Circuit Operation Radiator Cooling Fan Motor: Description and Operation Circuit Operation Cooling Fan Modules Circuit Operation The radiator fan system used in this vehicle uses a solid state relay that controls the speed of the radiator fan. Power for the relay is supplied on circuit A16 This circuit is HOT at all times and protected by a 30 Amp fuse located in the Power Distribution Center (PDC). Ground for the coil side of the relay is controlled by the Powertrain Control Module (PCM). When the PCM determines the need for fan operation the PCM supplies the ground path for circuit K173. This circuit connects to cavity 18 of the PCM connector. From the relay, circuit C25 connects to the radiator fan motor(s). On vehicles equipped with the manual transmission only one radiator fan is used. For vehicles equipped with an automatic transmission there are two radiator fans used. Ground for the radiator fans is supplied on circuit Z1. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Description and Operation > Circuit Operation > Page 1716 Radiator Cooling Fan Motor: Description and Operation Cooling Fan Motor Description The radiator fan system used in this vehicle uses a solid state relay (Pulse Width Module) that controls the speed of the radiator fan. A 5 volt signal is supplied to the Pulse Width Module (PWM). The PCM provides a pulsed ground for the PWM. Depending on the amount of pulse on time, the PWM puts out a proportional voltage to the fan motor at the lower speed. For instance, if the on time is 30 percent, then the voltage to the fan motor would be 3.6 volts. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Description and Operation > Circuit Operation > Page 1717 Radiator Cooling Fan Motor: Description and Operation Radiator Fan Control Cooling Fan Modules Fan control is accomplished in two ways. The fan always runs when the compressor clutch is engaged. - The fan is also turned on by the temperature of the coolant which is sensed by the coolant temperature sensor. The coolant temperature sensor sends the message to the Powertrain Control Module (PCM). The (PCM) turns on the fan through the Pulse Width Module (PWM). Switching through the (PCM) provides fan control for the following conditions: 1. Fan will not run when cranking engine no matter what coolant temperature is. 2. Fan will run when the A/C clutch is engaged and low pressure cutout switch is closed. 3. At vehicle speeds over 40 mph, fan will run only if coolant temperature reaches 230°F (110°C) and fan will turn off when temperature drops to 220°F (104°C). 4. At vehicle speeds under 40 mph, fan will run when coolant temperature reaches 215°F (102°C) and fan will turn off when temperature drops 200° F (93°C). 5. To prevent steaming, the fan will run with engine at idle speed and only for three minutes, when ambient temperature is below 60°F (16°C) and coolant temperature is between 100-207°F (38-97°C). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Description and Operation > Page 1718 Radiator Cooling Fan Motor: Service and Repair WARNING: Do not disassemble the fan motor from the support bracket. NOTE: Electric fan motor is serviced as an assembly with the fan module. REMOVAL 1. Disconnect fan motor leads from module. Servicing Fan Module 2. Remove fan module fasteners from radiator. INSTALLATION 1. Install module to radiator. Torque shroud to radiator fasteners to 7.3 Nm (65 inch lbs.). 2. Connect fan motor lead. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7692 > May > 98 > Recall- Radiator Fan Relay Technical Service Bulletin # 7692 Date: 980501 Recall- Radiator Fan Relay No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay Models: 1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. IMPORTANT: This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan Relay Packages, PN CKF07690, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 1 Wiring Jumper Assembly 2 Tie Straps California Recall Completion Label Requirement There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealers are requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1727 Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action please contact your Zone Service Office. A. Install the Jumper Harness 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Raise the vehicle on an appropriate hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1728 3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1). 4. Disconnect the fan motor wiring harness connector from the fan support (if necessary). 5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support. 6. Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that the connector faces toward the outboard (left) side of the vehicle (Figure 2). 7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2). 8. Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the locked position. 9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position. 10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps. NOTE: Make sure that the wiring does not interfere with any other components. B. Replace the Radiator Fan Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1729 1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3). 2. Disconnect the radiator fan relay wiring connector. 3. Remove and discard the radiator fan relay. 4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws. 5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 6. Lower the vehicle. 7. Connect the negative battery cable. C. Install the Authorized Label 1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086). 2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment. D. Complete Proof of Correction Form 1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^ This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant ("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. ^ Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number for TSB 07-07-97 and 07-04-98 is being canceled. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1730 ^ For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of those vehicles. Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is... The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumper harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. How the state knows that the recall has been performed... State of California regulations require Chrysler to provide the Department of Motor Vehicles with a record of all vehicles which have not had the recall service performed. If your vehicle is not on this list the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We are sorry for any inconvenience but trust you understand our interest in clean air and in your continued satisfaction with our products. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7691 > May > 98 > Recall - Radiator Fan Relay Technical Service Bulletin # 7691 Date: 980501 Recall - Radiator Fan Relay No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay Models: 1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. IMPORTANT: This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan Relay Packages, PN CKF07690, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 1 Wiring Jumper Assembly 2 Tie Straps California Recall Completion Label Requirement There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealers are requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1735 Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action please contact your Zone Service Office. A. Install the Jumper Harness 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Raise the vehicle on an appropriate hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1736 3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1). 4. Disconnect the fan motor wiring harness connector from the fan support (if necessary). 5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support. 6. Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that the connector faces toward the outboard (left) side of the vehicle (Figure 2). 7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2). 8. Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the locked position. 9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position. 10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps. NOTE: Make sure that the wiring does not interfere with any other components. B. Replace the Radiator Fan Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1737 1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3). 2. Disconnect the radiator fan relay wiring connector. 3. Remove and discard the radiator fan relay. 4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws. 5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 6. Lower the vehicle. 7. Connect the negative battery cable. C. Install the Authorized Label 1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086). 2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment. D. Complete Proof of Correction Form 1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^ This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant ("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. ^ Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number for TSB 07-07-97 and 07-04-98 is being canceled. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1738 ^ For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of those vehicles. Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is... The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumper harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... ^ If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If you are still unable to obtain the repair as described in this letter within a reasonable time, you may also contact the Vehicle Programs and Compliance Division of the Environmental Protection Agency (6405J), 401 M Street, S.W., Washington, D.C. 20460. In order to ensure your full protection under the emission warranty made applicable to your vehicle under Federal law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack of proper maintenance of your vehicle. Further, without this repair your vehicle may fail a state or local emission inspection test. We're sorry for any inconvenience, but trust that you understand our interest in clean air and your continuing satisfaction with our product. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats Technical Service Bulletin # 07-04-98 Date: 980417 Cooling System - Fan ON Continuously/Overheats NO: 07-04-98 GROUP: Cooling DATE: Apr. 17, 1998 SUBJECT: Vehicle Overheats (Radiator Fan Inoperative) Or Radiator Fan Runs Continuously THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-97 DATED FEBRUARY 20, 1998 WHICH SHOULD BE NOTED IN THE 1997 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-98004). THE REVISION PROVIDES A NEW PART NUMBER FOR THE RADIATOR FAN RELAY. THE CHANGE IS HIGHLIGHTED WITH ASTERISKS. MODELS: 1997 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT AT TOLUCA ASSEMBLY PRIOR TO SEPTEMBER 11, 1997 (MDH 0911XX). TOLUCA ASSEMBLY IS DESIGNATED BY A "T" IN THE ELEVENTH POSITION OF THE VEHICLE IDENTIFICATION NUMBER. SYMPTOM/CONDITION: Vehicle overheats or radiator fan continues to run. DIAGNOSIS: Actuate the radiator fan relay using the DRB III. If the radiator fan does not come on or fan runs continuously, perform the Repair Procedure. PARTS REQUIRED: 1 05293157AA Jumper Wire With Diode, Radiator Fan **1 04707286 Relay, Radiator Fan** 2 06015756 Tie Strap POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-12-92 0.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves installing a radiator fan jumper wire assembly into the headlamp and dash wiring harness, and replacing the solid state relay. 1. Raise the hood and disconnect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 1744 2. Raise the vehicle on a suitable hoist. 3. Locate the left (driver's side) black fan motor connector. Retract the red latch on the two-way female connector, depress the thumb latch, and disconnect the connector from the fan (Figure 1). If the wiring to the fan motor is clipped into the fan support, gently pry it out of the hole so the fan is not damaged. 4. Pry out the two christmas tree type retainers located on the lower radiator enclosure reinforcement. 5. Install the jumper wire assembly (p/n 052931 57AA) between the radiator fan and the headlamp and dash harness: A. Attach the black two-way male connector with the clip into the outboard hole, so the connector faces outboard toward the left side of the vehicle. Attach the second clip into the inboard hole of the lower reinforcement that the original wiring came out of (Figure 2). B. Connect the original two-way black connector to the new mating connector installed in the previous step and slide the red latch into the locked position. 6. Connect the two-way female black connector on the new jumper assembly to the fan connector and slide the red latch into the locked position. If the original wiring to the fan was clipped into the fan support, snap the new clip on the jumper into the same hole. 7. Bundle the excess original fan wiring and tie strap to the main bundle of vehicle wiring in the front left corner in two places. NOTE: ENSURE THAT THE WIRING BUNDLE IS SECURE AND DOES NOT INTERFERE WITH ANY OTHER COMPONENTS. 8. The solid state fan relay is located on the left front rail. Retract the red latch on the black four-way connector and disconnect from the solid state fan relay. 9. Remove the two screws that secure the relay to the side of the left front rail and remove the relay. 10. Install the new solid state fan relay ** (p/n 04707286)** and locate the index pin on the relay into the locator hole in the rail. Secure with the two screws and torque to 5 N.m (45 in.lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 1745 11. Connect the four way connector and slide the red latch into the locked position. 12. Lower the vehicle and connect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions Solid State Fan Relay: All Technical Service Bulletins Cooling System - Cooling Fan Relay Pin-Out Revisions NUMBER: 26-06-98D GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.0L, 2.4L, 2.5L, 3.3L, 3.5L SFI Diagnostic Manual - Publication Number 81-699-96040 DESCRIPTION OF CHANGES Revision to the PL body radiator fan relay connector pin out Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1751 10 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1752 49 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1753 110 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1754 111 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay Technical Service Bulletin # 7692 Date: 980501 Recall- Radiator Fan Relay No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay Models: 1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. IMPORTANT: This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan Relay Packages, PN CKF07690, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 1 Wiring Jumper Assembly 2 Tie Straps California Recall Completion Label Requirement There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealers are requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1759 Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action please contact your Zone Service Office. A. Install the Jumper Harness 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Raise the vehicle on an appropriate hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1760 3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1). 4. Disconnect the fan motor wiring harness connector from the fan support (if necessary). 5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support. 6. Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that the connector faces toward the outboard (left) side of the vehicle (Figure 2). 7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2). 8. Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the locked position. 9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position. 10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps. NOTE: Make sure that the wiring does not interfere with any other components. B. Replace the Radiator Fan Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1761 1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3). 2. Disconnect the radiator fan relay wiring connector. 3. Remove and discard the radiator fan relay. 4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws. 5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 6. Lower the vehicle. 7. Connect the negative battery cable. C. Install the Authorized Label 1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086). 2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment. D. Complete Proof of Correction Form 1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^ This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant ("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. ^ Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number for TSB 07-07-97 and 07-04-98 is being canceled. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1762 ^ For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of those vehicles. Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is... The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumper harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. How the state knows that the recall has been performed... State of California regulations require Chrysler to provide the Department of Motor Vehicles with a record of all vehicles which have not had the recall service performed. If your vehicle is not on this list the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We are sorry for any inconvenience but trust you understand our interest in clean air and in your continued satisfaction with our products. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay Technical Service Bulletin # 7691 Date: 980501 Recall - Radiator Fan Relay No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay Models: 1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. IMPORTANT: This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan Relay Packages, PN CKF07690, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 1 Wiring Jumper Assembly 2 Tie Straps California Recall Completion Label Requirement There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealers are requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1767 Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action please contact your Zone Service Office. A. Install the Jumper Harness 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Raise the vehicle on an appropriate hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1768 3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1). 4. Disconnect the fan motor wiring harness connector from the fan support (if necessary). 5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support. 6. Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that the connector faces toward the outboard (left) side of the vehicle (Figure 2). 7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2). 8. Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the locked position. 9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position. 10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps. NOTE: Make sure that the wiring does not interfere with any other components. B. Replace the Radiator Fan Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1769 1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3). 2. Disconnect the radiator fan relay wiring connector. 3. Remove and discard the radiator fan relay. 4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws. 5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 6. Lower the vehicle. 7. Connect the negative battery cable. C. Install the Authorized Label 1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086). 2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment. D. Complete Proof of Correction Form 1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^ This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant ("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. ^ Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number for TSB 07-07-97 and 07-04-98 is being canceled. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1770 ^ For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of those vehicles. Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is... The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumper harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... ^ If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If you are still unable to obtain the repair as described in this letter within a reasonable time, you may also contact the Vehicle Programs and Compliance Division of the Environmental Protection Agency (6405J), 401 M Street, S.W., Washington, D.C. 20460. In order to ensure your full protection under the emission warranty made applicable to your vehicle under Federal law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack of proper maintenance of your vehicle. Further, without this repair your vehicle may fail a state or local emission inspection test. We're sorry for any inconvenience, but trust that you understand our interest in clean air and your continuing satisfaction with our product. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats Technical Service Bulletin # 07-04-98 Date: 980417 Cooling System - Fan ON Continuously/Overheats NO: 07-04-98 GROUP: Cooling DATE: Apr. 17, 1998 SUBJECT: Vehicle Overheats (Radiator Fan Inoperative) Or Radiator Fan Runs Continuously THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-97 DATED FEBRUARY 20, 1998 WHICH SHOULD BE NOTED IN THE 1997 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-98004). THE REVISION PROVIDES A NEW PART NUMBER FOR THE RADIATOR FAN RELAY. THE CHANGE IS HIGHLIGHTED WITH ASTERISKS. MODELS: 1997 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT AT TOLUCA ASSEMBLY PRIOR TO SEPTEMBER 11, 1997 (MDH 0911XX). TOLUCA ASSEMBLY IS DESIGNATED BY A "T" IN THE ELEVENTH POSITION OF THE VEHICLE IDENTIFICATION NUMBER. SYMPTOM/CONDITION: Vehicle overheats or radiator fan continues to run. DIAGNOSIS: Actuate the radiator fan relay using the DRB III. If the radiator fan does not come on or fan runs continuously, perform the Repair Procedure. PARTS REQUIRED: 1 05293157AA Jumper Wire With Diode, Radiator Fan **1 04707286 Relay, Radiator Fan** 2 06015756 Tie Strap POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-12-92 0.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves installing a radiator fan jumper wire assembly into the headlamp and dash wiring harness, and replacing the solid state relay. 1. Raise the hood and disconnect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 1775 2. Raise the vehicle on a suitable hoist. 3. Locate the left (driver's side) black fan motor connector. Retract the red latch on the two-way female connector, depress the thumb latch, and disconnect the connector from the fan (Figure 1). If the wiring to the fan motor is clipped into the fan support, gently pry it out of the hole so the fan is not damaged. 4. Pry out the two christmas tree type retainers located on the lower radiator enclosure reinforcement. 5. Install the jumper wire assembly (p/n 052931 57AA) between the radiator fan and the headlamp and dash harness: A. Attach the black two-way male connector with the clip into the outboard hole, so the connector faces outboard toward the left side of the vehicle. Attach the second clip into the inboard hole of the lower reinforcement that the original wiring came out of (Figure 2). B. Connect the original two-way black connector to the new mating connector installed in the previous step and slide the red latch into the locked position. 6. Connect the two-way female black connector on the new jumper assembly to the fan connector and slide the red latch into the locked position. If the original wiring to the fan was clipped into the fan support, snap the new clip on the jumper into the same hole. 7. Bundle the excess original fan wiring and tie strap to the main bundle of vehicle wiring in the front left corner in two places. NOTE: ENSURE THAT THE WIRING BUNDLE IS SECURE AND DOES NOT INTERFERE WITH ANY OTHER COMPONENTS. 8. The solid state fan relay is located on the left front rail. Retract the red latch on the black four-way connector and disconnect from the solid state fan relay. 9. Remove the two screws that secure the relay to the side of the left front rail and remove the relay. 10. Install the new solid state fan relay ** (p/n 04707286)** and locate the index pin on the relay into the locator hole in the rail. Secure with the two screws and torque to 5 N.m (45 in.lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 1776 11. Connect the four way connector and slide the red latch into the locked position. 12. Lower the vehicle and connect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions Solid State Fan Relay: All Technical Service Bulletins Cooling System - Cooling Fan Relay Pin-Out Revisions NUMBER: 26-06-98D GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.0L, 2.4L, 2.5L, 3.3L, 3.5L SFI Diagnostic Manual - Publication Number 81-699-96040 DESCRIPTION OF CHANGES Revision to the PL body radiator fan relay connector pin out Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1782 10 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1783 49 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1784 110 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1785 111 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats Technical Service Bulletin # 07-04-98 Date: 980417 Cooling System - Fan ON Continuously/Overheats NO: 07-04-98 GROUP: Cooling DATE: Apr. 17, 1998 SUBJECT: Vehicle Overheats (Radiator Fan Inoperative) Or Radiator Fan Runs Continuously THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-97 DATED FEBRUARY 20, 1998 WHICH SHOULD BE NOTED IN THE 1997 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-98004). THE REVISION PROVIDES A NEW PART NUMBER FOR THE RADIATOR FAN RELAY. THE CHANGE IS HIGHLIGHTED WITH ASTERISKS. MODELS: 1997 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT AT TOLUCA ASSEMBLY PRIOR TO SEPTEMBER 11, 1997 (MDH 0911XX). TOLUCA ASSEMBLY IS DESIGNATED BY A "T" IN THE ELEVENTH POSITION OF THE VEHICLE IDENTIFICATION NUMBER. SYMPTOM/CONDITION: Vehicle overheats or radiator fan continues to run. DIAGNOSIS: Actuate the radiator fan relay using the DRB III. If the radiator fan does not come on or fan runs continuously, perform the Repair Procedure. PARTS REQUIRED: 1 05293157AA Jumper Wire With Diode, Radiator Fan **1 04707286 Relay, Radiator Fan** 2 06015756 Tie Strap POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-12-92 0.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves installing a radiator fan jumper wire assembly into the headlamp and dash wiring harness, and replacing the solid state relay. 1. Raise the hood and disconnect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 1790 2. Raise the vehicle on a suitable hoist. 3. Locate the left (driver's side) black fan motor connector. Retract the red latch on the two-way female connector, depress the thumb latch, and disconnect the connector from the fan (Figure 1). If the wiring to the fan motor is clipped into the fan support, gently pry it out of the hole so the fan is not damaged. 4. Pry out the two christmas tree type retainers located on the lower radiator enclosure reinforcement. 5. Install the jumper wire assembly (p/n 052931 57AA) between the radiator fan and the headlamp and dash harness: A. Attach the black two-way male connector with the clip into the outboard hole, so the connector faces outboard toward the left side of the vehicle. Attach the second clip into the inboard hole of the lower reinforcement that the original wiring came out of (Figure 2). B. Connect the original two-way black connector to the new mating connector installed in the previous step and slide the red latch into the locked position. 6. Connect the two-way female black connector on the new jumper assembly to the fan connector and slide the red latch into the locked position. If the original wiring to the fan was clipped into the fan support, snap the new clip on the jumper into the same hole. 7. Bundle the excess original fan wiring and tie strap to the main bundle of vehicle wiring in the front left corner in two places. NOTE: ENSURE THAT THE WIRING BUNDLE IS SECURE AND DOES NOT INTERFERE WITH ANY OTHER COMPONENTS. 8. The solid state fan relay is located on the left front rail. Retract the red latch on the black four-way connector and disconnect from the solid state fan relay. 9. Remove the two screws that secure the relay to the side of the left front rail and remove the relay. 10. Install the new solid state fan relay ** (p/n 04707286)** and locate the index pin on the relay into the locator hole in the rail. Secure with the two screws and torque to 5 N.m (45 in.lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 1791 11. Connect the four way connector and slide the red latch into the locked position. 12. Lower the vehicle and connect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1797 10 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1798 49 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1799 110 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1800 111 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay Technical Service Bulletin # 7692 Date: 980501 Recall- Radiator Fan Relay No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay Models: 1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. IMPORTANT: This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan Relay Packages, PN CKF07690, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 1 Wiring Jumper Assembly 2 Tie Straps California Recall Completion Label Requirement There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealers are requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1805 Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action please contact your Zone Service Office. A. Install the Jumper Harness 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Raise the vehicle on an appropriate hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1806 3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1). 4. Disconnect the fan motor wiring harness connector from the fan support (if necessary). 5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support. 6. Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that the connector faces toward the outboard (left) side of the vehicle (Figure 2). 7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2). 8. Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the locked position. 9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position. 10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps. NOTE: Make sure that the wiring does not interfere with any other components. B. Replace the Radiator Fan Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1807 1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3). 2. Disconnect the radiator fan relay wiring connector. 3. Remove and discard the radiator fan relay. 4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws. 5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 6. Lower the vehicle. 7. Connect the negative battery cable. C. Install the Authorized Label 1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086). 2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment. D. Complete Proof of Correction Form 1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^ This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant ("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. ^ Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number for TSB 07-07-97 and 07-04-98 is being canceled. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1808 ^ For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of those vehicles. Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is... The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumper harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. How the state knows that the recall has been performed... State of California regulations require Chrysler to provide the Department of Motor Vehicles with a record of all vehicles which have not had the recall service performed. If your vehicle is not on this list the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We are sorry for any inconvenience but trust you understand our interest in clean air and in your continued satisfaction with our products. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay Technical Service Bulletin # 7691 Date: 980501 Recall - Radiator Fan Relay No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay Models: 1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. IMPORTANT: This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan Relay Packages, PN CKF07690, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 1 Wiring Jumper Assembly 2 Tie Straps California Recall Completion Label Requirement There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealers are requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1813 Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action please contact your Zone Service Office. A. Install the Jumper Harness 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Raise the vehicle on an appropriate hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1814 3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1). 4. Disconnect the fan motor wiring harness connector from the fan support (if necessary). 5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support. 6. Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that the connector faces toward the outboard (left) side of the vehicle (Figure 2). 7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2). 8. Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the locked position. 9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position. 10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps. NOTE: Make sure that the wiring does not interfere with any other components. B. Replace the Radiator Fan Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1815 1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3). 2. Disconnect the radiator fan relay wiring connector. 3. Remove and discard the radiator fan relay. 4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws. 5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 6. Lower the vehicle. 7. Connect the negative battery cable. C. Install the Authorized Label 1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086). 2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment. D. Complete Proof of Correction Form 1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^ This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant ("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. ^ Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number for TSB 07-07-97 and 07-04-98 is being canceled. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1816 ^ For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of those vehicles. Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is... The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumper harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... ^ If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If you are still unable to obtain the repair as described in this letter within a reasonable time, you may also contact the Vehicle Programs and Compliance Division of the Environmental Protection Agency (6405J), 401 M Street, S.W., Washington, D.C. 20460. In order to ensure your full protection under the emission warranty made applicable to your vehicle under Federal law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack of proper maintenance of your vehicle. Further, without this repair your vehicle may fail a state or local emission inspection test. We're sorry for any inconvenience, but trust that you understand our interest in clean air and your continuing satisfaction with our product. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Page 1817 Solid State Fan Relay: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Page 1818 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Page 1819 Solid State Relay Solid State Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions Solid State Fan Relay: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1822 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1823 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1824 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1825 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1826 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1827 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1828 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1829 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1830 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1831 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1832 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1833 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1834 Solid State Fan Relay: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1835 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1836 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1837 Radiator Fan Relay Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1838 Solid State Fan Relay: Electrical Diagrams Dual Cooling Fans A/C & Heater System -- Sheet 8w-42-4 Chrysler Does not provide a wiring diagram for dual fans on 95-98 model year Neons. This diagram is for the 99 model year and is presented for reference only. Single Cooling Fan Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1839 A/C And Heat Part 1 of 4 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1840 A/C And Heat Part 2 Of 4 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1841 A/C And Heat Part 3 Of 4 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1842 A/C And Heat Part 4 Of 4 The OE does not show a wiring diagram showing the dual fan option specifically until 1999 but the dual fan option is mentioned. Additionally, the Radiator Fan Control is shown as a portion of the A/C circuit and as a portion of the PCM circuit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Page 1843 Solid State Fan Relay: Description and Operation Radiator Fan Control Module -PCM Output The radiator fan runs when coolant temperature and A/C system pressure demand cooling. The radiator fan circuit contains a Pulse Width Module (PWM) this is shown on the wiring as the Solid State Fan Relay. A 5 volt signal is supplied to the PWM. The PCM provides a pulsed ground for the PWM. Depending upon the amount of pulse on time, the PWM puts out a proportional voltage to the fan motor at the lower speed. For instance, if the on time is 30 percent, then the voltage to the fan motor will be 3.6 volts. When engine coolant reaches approximately 99°C (210°F) the PCM grounds the PWM relay. When the PCM grounds the relay it operates at a 30% duty cycle and immediately ramps up to 100% duty cycle. The PCM de-energizes the PWM relay when coolant temperature drops to approximately 93°C (199°F). Also, when the air conditioning pressure switch closes, the PCM grounds the PWM. The air conditioning switch closes at 285 psi ± 10 psi. When air conditioning pressure drops approximately 40 psi, the pressure switch opens and the fan turns off. The PWM relay is located on the left front inner frame just behind the radiator. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair Fan Blade: Service and Repair NOTE: There are no repairs to be made to the fan. If the fan is warped, cracked, or otherwise damaged, it must be replaced with only the recommended part for adequate strength, performance and safety. REMOVAL To remove fan from motor shaft, bench support the motor and motor shaft, while removing the fan retaining clip, so that the shaft and motor will not be damaged by excessive force. Do not permit the fan blades to touch the bench. NOTE: Surface burr removal may be required to remove fan from motor shaft. INSTALLATION To install fan on motor shaft, slide the fan over shaft. Support motor and shaft as above while installing fan retaining clip. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 18 Nm (165 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1851 Engine Coolant Temperature Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1852 Engine Coolant Temperature Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1853 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig.13 Engine Coolant Temperature Sensor-DOHC PURPOSE The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. - The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. OPERATION As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The coolant sensor threads into the intake manifold next to the thermostat housing (Fig. 13). New sensors have sealant applied to the threads. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. The sensor also operates the engine cool and temperature gauge in the instrument cluster on circuit G20. See: Lamps and Indicators - Cooling System/Temperature Gauge/Description and Operation From circuit K2 the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes causing a change in current draw. The K2 circuit connects to cavity 26 of the PCM connector. The PCM provides ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig. 80 Engine Coolant Temperature Sensor Location-DOHC 1. With the key off, disconnect wire harness connector from coolant temperature sensor (Fig. 80). Fig. 27 Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 27). The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 28 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing > Page 1856 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Helpful Information The engine coolant temperature sensor is case grounded. The case ground provides the ground for the coolant temperature gauge circuit G20. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 1857 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig.39 Engine Coolant Temperature Sensor-DOHC NOTE: The engine coolant temperature sensor threads into the rear of the cylinder head. New sensors have sealant applied to the threads. REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. - Tighten to 18 Nm (165 in lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Description and Operation Fan Shroud: Description and Operation GENERAL INFORMATION Some fan shrouds are equipped with flapped doors to prevent the shroud from restricting air flow at high speeds. PURPOSE All vehicles have fan shrouds to improve fan air flow efficiency. The shroud supports the electric fan motor and fan. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair Heater Hose: Service and Repair CAUTION: When removing hoses from heater core inlet or outlet nipples DO NOT exert excess pressure. The heater core may become damaged and leak engine coolant. NOTE: Review Cooling System Precautions before proceeding with this operation. REMOVAL 1. Drain engine cooling system. 2. Remove clamp at end of heater hose to be removed. Heater Hose Quick Connect 3. ON Right Hand Drive (RHD) vehicles, heater hoses at the heater core connection have quick connects. The quick connect consist of two pieces; a quick connect and insert. The quick connect is removed by compressing the insert with a pliers, and pulling the quick connect free of the insert/nipple. Carefully compressed insert pulling the quick connect from connector nipple. The insert will remain on the connector nipple as the quick connect is removed. 4. Remove the heater hose clamp from the heater hose at the block and remove hose. INSTALLATION NOTE: The insert should be removed from the connector nipple and placed inside of the quick connect before reassembly. For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation CIRCUIT OPERATION The temperature gauge is connected to the engine coolant temperature sensor on the G20 circuit. The engine coolant temperature sensor for the gauge is a combination unit. One side of the unit is used for the Powertrain Control Module (PCM) and the other side for the cluster. The sending unit is case grounded to the engine. The logic driven gauge moves in response to the measured resistance of the engine coolant temperature sending unit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 1868 Temperature Gauge: Testing and Inspection Engine Coolant Temperature Sensor 1. Disconnect the coolant temperature sensor. 2. Turn ignition switch ON. The temperature gauge should be at its lowest position. Turn ignition switch OFF 3. Ground temperature gauge sending unit connector Pin 3. Turn ignition switch ON. The temperature gauge should be at its highest position. After the seat belt lamp goes out, the cluster should chime for about Eight Seconds. a. If OK, check temperature sending unit connector for proper connection. If connections are OK, replace the sending unit. b. If not OK, and the high temperature chime sounds but the gauge shows cold, replace the gauge assembly If gauge is still not working, replace the printed circuit board. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair Radiator Drain Plug: Service and Repair CAUTION: Plastic tanks, while stronger then brass are subject to damage by impact, such as wrenches. REMOVAL Turn the drain cock stem counterclockwise to unscrew the stem. When the stem is unscrewed to the end of the threads, pull the stem from the radiator tank. INSTALLATION 1. Push the draincock assembly body into the tank opening. 2. Tighten the draincock stem by turning clockwise to 2.0 - 2.7 Nm (18 - 25 inch lbs.) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation Radiator Cap: Description and Operation GENERAL INFORMATION The cooling system is equipped with a pressure cap that releases pressure at some point within a range of 97 - 124 kPa (14 - 18 psi). The system will operate at higher than atmospheric pressure, which raises the coolant boiling point, allowing increased radiator cooling capacity. VENT VALVE There is a vent valve in the center of the cap that allows a small coolant flow to the Coolant Recovery System (CRS) tank. If the valve is stuck shut, the radiator hoses will collapse on cool-down. Clean the vent valve to ensure proper sealing when boiling point is reached. GASKET There is a gasket in the cap that seals to the top of the filler neck so that vacuum is maintained to draw coolant back into the system from the coolant reserve system tank. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Radiator Cap: Initial Inspection and Diagnostic Overview Hold the cap in your hand, right side up. The vent valve at the bottom of the cap should open with a slight pull. If the rubber gasket has swollen preventing the valve from opening, replace the cap. If any light can be seen between vent valve and the rubber gasket, replace the cap. Use only a replacement cap that has a spring to hold the vent shut. NOTE: A replacement cap must be of the type designed for coolant reserve systems. This design ensures system pressurization. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1878 Radiator Cap: Component Tests and General Diagnostics Radiator Cap - Pressure Testing Dip the pressure cap in water; clean off any deposits on the vent valve or its seat, and apply the cap to end of radiator pressure tester. Working the plunger, increase the pressure to 104 kPa (15 psi) on the gauge. If the pressure cap fails to hold pressure of at least 97 kPa (14 psi), replace the cap. CAUTION: The radiator pressure tester is very sensitive to small air leaks that will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to the tool. Turn the tool upside down, and recheck the pressure cap to confirm that the cap is faulty. NOTE: If the pressure cap tests properly while positioned the on radiator pressure tester, but will not hold pressure or vacuum when positioned on the filler neck, inspect the filler neck and cap top gasket for irregularities that may prevent the cap from sealing properly. Radiator Cap to Filler Neck Seal - Pressure Relief Check The pressure cap upper gasket (seal) pressure relief can be checked by removing the overflow hose at the radiator filler neck nipple. Attach the radiator pressure tester to the filler neck nipple, and pump air into the system. The pressure cap upper gasket should relieve pressure at 69 - 124 kPa (10 - 18 psi) , and hold pressure at 55 kPa (8 psi) minimum. WARNING: THE WARNING WORDS DO NOT OPEN HOT ON THE PRESSURE CAP IS A SAFETY PRECAUTION. WHEN HOT, THE Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1879 COOLING SYSTEM BUILDS UP PRESSURE. TO PREVENT SCALDING OR OTHER INJURY, THE PRESSURE CAP SHOULD NOT BE REMOVED WHILE THE SYSTEM IS HOT AND/OR UNDER PRESSURE. There is no need to remove the pressure cap at any time except for the following purposes: - Check and adjust coolant freeze point - Refill system with new coolant - Conducting service procedures - Checking for leaks WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE REMOVING CAP. PLACE A SHOP TOWEL OVER THE CAP, AND WITHOUT PUSHING DOWN, ROTATE IT COUNTERCLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE. WHEN THE SYSTEM STOPS PUSHING COOLANT AND STEAM INTO THE COOLANT RECOVERY SYSTEM (CRS) TANK AND PRESSURE DROPS, PUSH DOWN ON THE CAP AND REMOVE IT COMPLETELY. SQUEEZING THE RADIATOR INLET HOSE WITH A SHOP TOWEL (TO CHECK PRESSURE) BEFORE AND AFTER TURNING TO THE FIRST STOP IS RECOMMENDED. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Description and Operation Radiator Hose: Description and Operation WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE WORKING ON VEHICLE. RELIEVE PRESSURE BY PLACING A SHOP TOWEL OVER THE CAP AND WITHOUT PUSHING DOWN ROTATE IT COUNTER-CLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE AND WHEN THE SYSTEM STOPS PUSHING OUT COOLANT AND STEAM AND THE PRESSURE DROPS CONTINUE SERVICE. CAUTION: - Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clamp. Always wear safety glasses when servicing constant tension clamps. - A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only a original equipment clamp with matching number or letter. HOSES Radiator hoses should be routed without any kinks and indexed as designed. The use of molded hoses is recommended. A hardened, cracked, swollen or restricted hose should be replaced. Do not damage radiator inlet and outlet when loosening hoses. CLAMPS Spring type hose clamps are used in all applications. If replacement is necessary replace with the original Mopar equipment spring type clamp. The hose clamps are removed by using Special Tool 6094, or equivalent constant tension clamp pliers to compress hose clamp. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7692 > May > 98 > Recall- Radiator Fan Relay Technical Service Bulletin # 7692 Date: 980501 Recall- Radiator Fan Relay No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay Models: 1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. IMPORTANT: This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan Relay Packages, PN CKF07690, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 1 Wiring Jumper Assembly 2 Tie Straps California Recall Completion Label Requirement There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealers are requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1892 Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action please contact your Zone Service Office. A. Install the Jumper Harness 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Raise the vehicle on an appropriate hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1893 3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1). 4. Disconnect the fan motor wiring harness connector from the fan support (if necessary). 5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support. 6. Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that the connector faces toward the outboard (left) side of the vehicle (Figure 2). 7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2). 8. Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the locked position. 9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position. 10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps. NOTE: Make sure that the wiring does not interfere with any other components. B. Replace the Radiator Fan Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1894 1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3). 2. Disconnect the radiator fan relay wiring connector. 3. Remove and discard the radiator fan relay. 4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws. 5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 6. Lower the vehicle. 7. Connect the negative battery cable. C. Install the Authorized Label 1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086). 2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment. D. Complete Proof of Correction Form 1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^ This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant ("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. ^ Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number for TSB 07-07-97 and 07-04-98 is being canceled. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1895 ^ For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of those vehicles. Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is... The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumper harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. How the state knows that the recall has been performed... State of California regulations require Chrysler to provide the Department of Motor Vehicles with a record of all vehicles which have not had the recall service performed. If your vehicle is not on this list the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We are sorry for any inconvenience but trust you understand our interest in clean air and in your continued satisfaction with our products. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7691 > May > 98 > Recall - Radiator Fan Relay Technical Service Bulletin # 7691 Date: 980501 Recall - Radiator Fan Relay No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay Models: 1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. IMPORTANT: This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan Relay Packages, PN CKF07690, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 1 Wiring Jumper Assembly 2 Tie Straps California Recall Completion Label Requirement There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealers are requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1900 Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action please contact your Zone Service Office. A. Install the Jumper Harness 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Raise the vehicle on an appropriate hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1901 3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1). 4. Disconnect the fan motor wiring harness connector from the fan support (if necessary). 5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support. 6. Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that the connector faces toward the outboard (left) side of the vehicle (Figure 2). 7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2). 8. Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the locked position. 9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position. 10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps. NOTE: Make sure that the wiring does not interfere with any other components. B. Replace the Radiator Fan Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1902 1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3). 2. Disconnect the radiator fan relay wiring connector. 3. Remove and discard the radiator fan relay. 4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws. 5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 6. Lower the vehicle. 7. Connect the negative battery cable. C. Install the Authorized Label 1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086). 2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment. D. Complete Proof of Correction Form 1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^ This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant ("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. ^ Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number for TSB 07-07-97 and 07-04-98 is being canceled. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1903 ^ For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of those vehicles. Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is... The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumper harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... ^ If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If you are still unable to obtain the repair as described in this letter within a reasonable time, you may also contact the Vehicle Programs and Compliance Division of the Environmental Protection Agency (6405J), 401 M Street, S.W., Washington, D.C. 20460. In order to ensure your full protection under the emission warranty made applicable to your vehicle under Federal law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack of proper maintenance of your vehicle. Further, without this repair your vehicle may fail a state or local emission inspection test. We're sorry for any inconvenience, but trust that you understand our interest in clean air and your continuing satisfaction with our product. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats Technical Service Bulletin # 07-04-98 Date: 980417 Cooling System - Fan ON Continuously/Overheats NO: 07-04-98 GROUP: Cooling DATE: Apr. 17, 1998 SUBJECT: Vehicle Overheats (Radiator Fan Inoperative) Or Radiator Fan Runs Continuously THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-97 DATED FEBRUARY 20, 1998 WHICH SHOULD BE NOTED IN THE 1997 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-98004). THE REVISION PROVIDES A NEW PART NUMBER FOR THE RADIATOR FAN RELAY. THE CHANGE IS HIGHLIGHTED WITH ASTERISKS. MODELS: 1997 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT AT TOLUCA ASSEMBLY PRIOR TO SEPTEMBER 11, 1997 (MDH 0911XX). TOLUCA ASSEMBLY IS DESIGNATED BY A "T" IN THE ELEVENTH POSITION OF THE VEHICLE IDENTIFICATION NUMBER. SYMPTOM/CONDITION: Vehicle overheats or radiator fan continues to run. DIAGNOSIS: Actuate the radiator fan relay using the DRB III. If the radiator fan does not come on or fan runs continuously, perform the Repair Procedure. PARTS REQUIRED: 1 05293157AA Jumper Wire With Diode, Radiator Fan **1 04707286 Relay, Radiator Fan** 2 06015756 Tie Strap POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-12-92 0.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves installing a radiator fan jumper wire assembly into the headlamp and dash wiring harness, and replacing the solid state relay. 1. Raise the hood and disconnect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 1909 2. Raise the vehicle on a suitable hoist. 3. Locate the left (driver's side) black fan motor connector. Retract the red latch on the two-way female connector, depress the thumb latch, and disconnect the connector from the fan (Figure 1). If the wiring to the fan motor is clipped into the fan support, gently pry it out of the hole so the fan is not damaged. 4. Pry out the two christmas tree type retainers located on the lower radiator enclosure reinforcement. 5. Install the jumper wire assembly (p/n 052931 57AA) between the radiator fan and the headlamp and dash harness: A. Attach the black two-way male connector with the clip into the outboard hole, so the connector faces outboard toward the left side of the vehicle. Attach the second clip into the inboard hole of the lower reinforcement that the original wiring came out of (Figure 2). B. Connect the original two-way black connector to the new mating connector installed in the previous step and slide the red latch into the locked position. 6. Connect the two-way female black connector on the new jumper assembly to the fan connector and slide the red latch into the locked position. If the original wiring to the fan was clipped into the fan support, snap the new clip on the jumper into the same hole. 7. Bundle the excess original fan wiring and tie strap to the main bundle of vehicle wiring in the front left corner in two places. NOTE: ENSURE THAT THE WIRING BUNDLE IS SECURE AND DOES NOT INTERFERE WITH ANY OTHER COMPONENTS. 8. The solid state fan relay is located on the left front rail. Retract the red latch on the black four-way connector and disconnect from the solid state fan relay. 9. Remove the two screws that secure the relay to the side of the left front rail and remove the relay. 10. Install the new solid state fan relay ** (p/n 04707286)** and locate the index pin on the relay into the locator hole in the rail. Secure with the two screws and torque to 5 N.m (45 in.lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 1910 11. Connect the four way connector and slide the red latch into the locked position. 12. Lower the vehicle and connect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions Solid State Fan Relay: All Technical Service Bulletins Cooling System - Cooling Fan Relay Pin-Out Revisions NUMBER: 26-06-98D GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.0L, 2.4L, 2.5L, 3.3L, 3.5L SFI Diagnostic Manual - Publication Number 81-699-96040 DESCRIPTION OF CHANGES Revision to the PL body radiator fan relay connector pin out Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1916 10 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1917 49 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1918 110 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1919 111 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay Technical Service Bulletin # 7692 Date: 980501 Recall- Radiator Fan Relay No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay Models: 1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. IMPORTANT: This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan Relay Packages, PN CKF07690, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 1 Wiring Jumper Assembly 2 Tie Straps California Recall Completion Label Requirement There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealers are requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1924 Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action please contact your Zone Service Office. A. Install the Jumper Harness 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Raise the vehicle on an appropriate hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1925 3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1). 4. Disconnect the fan motor wiring harness connector from the fan support (if necessary). 5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support. 6. Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that the connector faces toward the outboard (left) side of the vehicle (Figure 2). 7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2). 8. Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the locked position. 9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position. 10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps. NOTE: Make sure that the wiring does not interfere with any other components. B. Replace the Radiator Fan Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1926 1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3). 2. Disconnect the radiator fan relay wiring connector. 3. Remove and discard the radiator fan relay. 4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws. 5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 6. Lower the vehicle. 7. Connect the negative battery cable. C. Install the Authorized Label 1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086). 2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment. D. Complete Proof of Correction Form 1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^ This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant ("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. ^ Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number for TSB 07-07-97 and 07-04-98 is being canceled. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1927 ^ For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of those vehicles. Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is... The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumper harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. How the state knows that the recall has been performed... State of California regulations require Chrysler to provide the Department of Motor Vehicles with a record of all vehicles which have not had the recall service performed. If your vehicle is not on this list the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We are sorry for any inconvenience but trust you understand our interest in clean air and in your continued satisfaction with our products. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay Technical Service Bulletin # 7691 Date: 980501 Recall - Radiator Fan Relay No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay Models: 1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. IMPORTANT: This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan Relay Packages, PN CKF07690, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 1 Wiring Jumper Assembly 2 Tie Straps California Recall Completion Label Requirement There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealers are requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1932 Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action please contact your Zone Service Office. A. Install the Jumper Harness 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Raise the vehicle on an appropriate hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1933 3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1). 4. Disconnect the fan motor wiring harness connector from the fan support (if necessary). 5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support. 6. Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that the connector faces toward the outboard (left) side of the vehicle (Figure 2). 7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2). 8. Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the locked position. 9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position. 10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps. NOTE: Make sure that the wiring does not interfere with any other components. B. Replace the Radiator Fan Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1934 1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3). 2. Disconnect the radiator fan relay wiring connector. 3. Remove and discard the radiator fan relay. 4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws. 5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 6. Lower the vehicle. 7. Connect the negative battery cable. C. Install the Authorized Label 1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086). 2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment. D. Complete Proof of Correction Form 1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^ This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant ("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. ^ Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number for TSB 07-07-97 and 07-04-98 is being canceled. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1935 ^ For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of those vehicles. Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is... The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumper harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... ^ If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If you are still unable to obtain the repair as described in this letter within a reasonable time, you may also contact the Vehicle Programs and Compliance Division of the Environmental Protection Agency (6405J), 401 M Street, S.W., Washington, D.C. 20460. In order to ensure your full protection under the emission warranty made applicable to your vehicle under Federal law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack of proper maintenance of your vehicle. Further, without this repair your vehicle may fail a state or local emission inspection test. We're sorry for any inconvenience, but trust that you understand our interest in clean air and your continuing satisfaction with our product. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats Technical Service Bulletin # 07-04-98 Date: 980417 Cooling System - Fan ON Continuously/Overheats NO: 07-04-98 GROUP: Cooling DATE: Apr. 17, 1998 SUBJECT: Vehicle Overheats (Radiator Fan Inoperative) Or Radiator Fan Runs Continuously THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-97 DATED FEBRUARY 20, 1998 WHICH SHOULD BE NOTED IN THE 1997 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-98004). THE REVISION PROVIDES A NEW PART NUMBER FOR THE RADIATOR FAN RELAY. THE CHANGE IS HIGHLIGHTED WITH ASTERISKS. MODELS: 1997 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT AT TOLUCA ASSEMBLY PRIOR TO SEPTEMBER 11, 1997 (MDH 0911XX). TOLUCA ASSEMBLY IS DESIGNATED BY A "T" IN THE ELEVENTH POSITION OF THE VEHICLE IDENTIFICATION NUMBER. SYMPTOM/CONDITION: Vehicle overheats or radiator fan continues to run. DIAGNOSIS: Actuate the radiator fan relay using the DRB III. If the radiator fan does not come on or fan runs continuously, perform the Repair Procedure. PARTS REQUIRED: 1 05293157AA Jumper Wire With Diode, Radiator Fan **1 04707286 Relay, Radiator Fan** 2 06015756 Tie Strap POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-12-92 0.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves installing a radiator fan jumper wire assembly into the headlamp and dash wiring harness, and replacing the solid state relay. 1. Raise the hood and disconnect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 1940 2. Raise the vehicle on a suitable hoist. 3. Locate the left (driver's side) black fan motor connector. Retract the red latch on the two-way female connector, depress the thumb latch, and disconnect the connector from the fan (Figure 1). If the wiring to the fan motor is clipped into the fan support, gently pry it out of the hole so the fan is not damaged. 4. Pry out the two christmas tree type retainers located on the lower radiator enclosure reinforcement. 5. Install the jumper wire assembly (p/n 052931 57AA) between the radiator fan and the headlamp and dash harness: A. Attach the black two-way male connector with the clip into the outboard hole, so the connector faces outboard toward the left side of the vehicle. Attach the second clip into the inboard hole of the lower reinforcement that the original wiring came out of (Figure 2). B. Connect the original two-way black connector to the new mating connector installed in the previous step and slide the red latch into the locked position. 6. Connect the two-way female black connector on the new jumper assembly to the fan connector and slide the red latch into the locked position. If the original wiring to the fan was clipped into the fan support, snap the new clip on the jumper into the same hole. 7. Bundle the excess original fan wiring and tie strap to the main bundle of vehicle wiring in the front left corner in two places. NOTE: ENSURE THAT THE WIRING BUNDLE IS SECURE AND DOES NOT INTERFERE WITH ANY OTHER COMPONENTS. 8. The solid state fan relay is located on the left front rail. Retract the red latch on the black four-way connector and disconnect from the solid state fan relay. 9. Remove the two screws that secure the relay to the side of the left front rail and remove the relay. 10. Install the new solid state fan relay ** (p/n 04707286)** and locate the index pin on the relay into the locator hole in the rail. Secure with the two screws and torque to 5 N.m (45 in.lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 1941 11. Connect the four way connector and slide the red latch into the locked position. 12. Lower the vehicle and connect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions Solid State Fan Relay: All Technical Service Bulletins Cooling System - Cooling Fan Relay Pin-Out Revisions NUMBER: 26-06-98D GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.0L, 2.4L, 2.5L, 3.3L, 3.5L SFI Diagnostic Manual - Publication Number 81-699-96040 DESCRIPTION OF CHANGES Revision to the PL body radiator fan relay connector pin out Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1947 10 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1948 49 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1949 110 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1950 111 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats Technical Service Bulletin # 07-04-98 Date: 980417 Cooling System - Fan ON Continuously/Overheats NO: 07-04-98 GROUP: Cooling DATE: Apr. 17, 1998 SUBJECT: Vehicle Overheats (Radiator Fan Inoperative) Or Radiator Fan Runs Continuously THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-97 DATED FEBRUARY 20, 1998 WHICH SHOULD BE NOTED IN THE 1997 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-98004). THE REVISION PROVIDES A NEW PART NUMBER FOR THE RADIATOR FAN RELAY. THE CHANGE IS HIGHLIGHTED WITH ASTERISKS. MODELS: 1997 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT AT TOLUCA ASSEMBLY PRIOR TO SEPTEMBER 11, 1997 (MDH 0911XX). TOLUCA ASSEMBLY IS DESIGNATED BY A "T" IN THE ELEVENTH POSITION OF THE VEHICLE IDENTIFICATION NUMBER. SYMPTOM/CONDITION: Vehicle overheats or radiator fan continues to run. DIAGNOSIS: Actuate the radiator fan relay using the DRB III. If the radiator fan does not come on or fan runs continuously, perform the Repair Procedure. PARTS REQUIRED: 1 05293157AA Jumper Wire With Diode, Radiator Fan **1 04707286 Relay, Radiator Fan** 2 06015756 Tie Strap POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-12-92 0.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves installing a radiator fan jumper wire assembly into the headlamp and dash wiring harness, and replacing the solid state relay. 1. Raise the hood and disconnect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 1955 2. Raise the vehicle on a suitable hoist. 3. Locate the left (driver's side) black fan motor connector. Retract the red latch on the two-way female connector, depress the thumb latch, and disconnect the connector from the fan (Figure 1). If the wiring to the fan motor is clipped into the fan support, gently pry it out of the hole so the fan is not damaged. 4. Pry out the two christmas tree type retainers located on the lower radiator enclosure reinforcement. 5. Install the jumper wire assembly (p/n 052931 57AA) between the radiator fan and the headlamp and dash harness: A. Attach the black two-way male connector with the clip into the outboard hole, so the connector faces outboard toward the left side of the vehicle. Attach the second clip into the inboard hole of the lower reinforcement that the original wiring came out of (Figure 2). B. Connect the original two-way black connector to the new mating connector installed in the previous step and slide the red latch into the locked position. 6. Connect the two-way female black connector on the new jumper assembly to the fan connector and slide the red latch into the locked position. If the original wiring to the fan was clipped into the fan support, snap the new clip on the jumper into the same hole. 7. Bundle the excess original fan wiring and tie strap to the main bundle of vehicle wiring in the front left corner in two places. NOTE: ENSURE THAT THE WIRING BUNDLE IS SECURE AND DOES NOT INTERFERE WITH ANY OTHER COMPONENTS. 8. The solid state fan relay is located on the left front rail. Retract the red latch on the black four-way connector and disconnect from the solid state fan relay. 9. Remove the two screws that secure the relay to the side of the left front rail and remove the relay. 10. Install the new solid state fan relay ** (p/n 04707286)** and locate the index pin on the relay into the locator hole in the rail. Secure with the two screws and torque to 5 N.m (45 in.lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 1956 11. Connect the four way connector and slide the red latch into the locked position. 12. Lower the vehicle and connect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1962 10 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1963 49 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1964 110 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 1965 111 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay Technical Service Bulletin # 7692 Date: 980501 Recall- Radiator Fan Relay No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay Models: 1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. IMPORTANT: This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan Relay Packages, PN CKF07690, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 1 Wiring Jumper Assembly 2 Tie Straps California Recall Completion Label Requirement There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealers are requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1970 Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action please contact your Zone Service Office. A. Install the Jumper Harness 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Raise the vehicle on an appropriate hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1971 3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1). 4. Disconnect the fan motor wiring harness connector from the fan support (if necessary). 5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support. 6. Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that the connector faces toward the outboard (left) side of the vehicle (Figure 2). 7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2). 8. Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the locked position. 9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position. 10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps. NOTE: Make sure that the wiring does not interfere with any other components. B. Replace the Radiator Fan Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1972 1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3). 2. Disconnect the radiator fan relay wiring connector. 3. Remove and discard the radiator fan relay. 4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws. 5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 6. Lower the vehicle. 7. Connect the negative battery cable. C. Install the Authorized Label 1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086). 2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment. D. Complete Proof of Correction Form 1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^ This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant ("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. ^ Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number for TSB 07-07-97 and 07-04-98 is being canceled. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 1973 ^ For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of those vehicles. Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is... The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumper harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. How the state knows that the recall has been performed... State of California regulations require Chrysler to provide the Department of Motor Vehicles with a record of all vehicles which have not had the recall service performed. If your vehicle is not on this list the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We are sorry for any inconvenience but trust you understand our interest in clean air and in your continued satisfaction with our products. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay Technical Service Bulletin # 7691 Date: 980501 Recall - Radiator Fan Relay No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay Models: 1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. IMPORTANT: This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan Relay Packages, PN CKF07690, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 1 Wiring Jumper Assembly 2 Tie Straps California Recall Completion Label Requirement There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealers are requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1978 Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action please contact your Zone Service Office. A. Install the Jumper Harness 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Raise the vehicle on an appropriate hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1979 3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1). 4. Disconnect the fan motor wiring harness connector from the fan support (if necessary). 5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support. 6. Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that the connector faces toward the outboard (left) side of the vehicle (Figure 2). 7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2). 8. Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the locked position. 9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position. 10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps. NOTE: Make sure that the wiring does not interfere with any other components. B. Replace the Radiator Fan Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1980 1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3). 2. Disconnect the radiator fan relay wiring connector. 3. Remove and discard the radiator fan relay. 4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws. 5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 6. Lower the vehicle. 7. Connect the negative battery cable. C. Install the Authorized Label 1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086). 2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment. D. Complete Proof of Correction Form 1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^ This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant ("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691 ^ Currently Located In California -- Recall # 7692 ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must be replaced and a jumper wire that contains a diode must be installed. ^ Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number for TSB 07-07-97 and 07-04-98 is being canceled. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 1981 ^ For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of those vehicles. Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is... The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat. In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored component violates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumper harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... ^ If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If you are still unable to obtain the repair as described in this letter within a reasonable time, you may also contact the Vehicle Programs and Compliance Division of the Environmental Protection Agency (6405J), 401 M Street, S.W., Washington, D.C. 20460. In order to ensure your full protection under the emission warranty made applicable to your vehicle under Federal law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack of proper maintenance of your vehicle. Further, without this repair your vehicle may fail a state or local emission inspection test. We're sorry for any inconvenience, but trust that you understand our interest in clean air and your continuing satisfaction with our product. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Page 1982 Solid State Fan Relay: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Page 1983 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Page 1984 Solid State Relay Solid State Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions Solid State Fan Relay: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1987 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1988 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1989 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1990 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1991 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1992 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1993 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1994 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1995 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1996 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1997 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1998 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1999 Solid State Fan Relay: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2000 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2001 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2002 Radiator Fan Relay Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2003 Solid State Fan Relay: Electrical Diagrams Dual Cooling Fans A/C & Heater System -- Sheet 8w-42-4 Chrysler Does not provide a wiring diagram for dual fans on 95-98 model year Neons. This diagram is for the 99 model year and is presented for reference only. Single Cooling Fan Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2004 A/C And Heat Part 1 of 4 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2005 A/C And Heat Part 2 Of 4 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2006 A/C And Heat Part 3 Of 4 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2007 A/C And Heat Part 4 Of 4 The OE does not show a wiring diagram showing the dual fan option specifically until 1999 but the dual fan option is mentioned. Additionally, the Radiator Fan Control is shown as a portion of the A/C circuit and as a portion of the PCM circuit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Page 2008 Solid State Fan Relay: Description and Operation Radiator Fan Control Module -PCM Output The radiator fan runs when coolant temperature and A/C system pressure demand cooling. The radiator fan circuit contains a Pulse Width Module (PWM) this is shown on the wiring as the Solid State Fan Relay. A 5 volt signal is supplied to the PWM. The PCM provides a pulsed ground for the PWM. Depending upon the amount of pulse on time, the PWM puts out a proportional voltage to the fan motor at the lower speed. For instance, if the on time is 30 percent, then the voltage to the fan motor will be 3.6 volts. When engine coolant reaches approximately 99°C (210°F) the PCM grounds the PWM relay. When the PCM grounds the relay it operates at a 30% duty cycle and immediately ramps up to 100% duty cycle. The PCM de-energizes the PWM relay when coolant temperature drops to approximately 93°C (199°F). Also, when the air conditioning pressure switch closes, the PCM grounds the PWM. The air conditioning switch closes at 285 psi ± 10 psi. When air conditioning pressure drops approximately 40 psi, the pressure switch opens and the fan turns off. The PWM relay is located on the left front inner frame just behind the radiator. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 18 Nm (165 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2014 Engine Coolant Temperature Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2015 Engine Coolant Temperature Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2016 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig.13 Engine Coolant Temperature Sensor-DOHC PURPOSE The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. - The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. OPERATION As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The coolant sensor threads into the intake manifold next to the thermostat housing (Fig. 13). New sensors have sealant applied to the threads. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. The sensor also operates the engine cool and temperature gauge in the instrument cluster on circuit G20. See: Lamps and Indicators - Cooling System/Temperature Gauge/Description and Operation From circuit K2 the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes causing a change in current draw. The K2 circuit connects to cavity 26 of the PCM connector. The PCM provides ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig. 80 Engine Coolant Temperature Sensor Location-DOHC 1. With the key off, disconnect wire harness connector from coolant temperature sensor (Fig. 80). Fig. 27 Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 27). The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 28 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing > Page 2019 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Helpful Information The engine coolant temperature sensor is case grounded. The case ground provides the ground for the coolant temperature gauge circuit G20. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 2020 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig.39 Engine Coolant Temperature Sensor-DOHC NOTE: The engine coolant temperature sensor threads into the rear of the cylinder head. New sensors have sealant applied to the threads. REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. - Tighten to 18 Nm (165 in lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation CIRCUIT OPERATION The temperature gauge is connected to the engine coolant temperature sensor on the G20 circuit. The engine coolant temperature sensor for the gauge is a combination unit. One side of the unit is used for the Powertrain Control Module (PCM) and the other side for the cluster. The sending unit is case grounded to the engine. The logic driven gauge moves in response to the measured resistance of the engine coolant temperature sending unit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 2024 Temperature Gauge: Testing and Inspection Engine Coolant Temperature Sensor 1. Disconnect the coolant temperature sensor. 2. Turn ignition switch ON. The temperature gauge should be at its lowest position. Turn ignition switch OFF 3. Ground temperature gauge sending unit connector Pin 3. Turn ignition switch ON. The temperature gauge should be at its highest position. After the seat belt lamp goes out, the cluster should chime for about Eight Seconds. a. If OK, check temperature sending unit connector for proper connection. If connections are OK, replace the sending unit. b. If not OK, and the high temperature chime sounds but the gauge shows cold, replace the gauge assembly If gauge is still not working, replace the printed circuit board. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Mechanical Specifications Thermostat: Mechanical Specifications Case Assembly Mounting Bolt ................................................................................................................................................... 17 20 Nm (12 - 14 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Mechanical Specifications > Page 2029 Thermostat: Pressure, Vacuum and Temperature Specifications Opening Temperature ......................................................................................................................... ......................................................... 90.5° C (195° F) Full Opening Temperature ............................. ............................................................................................................................................... 102° C (216° F) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2030 Thermostat: Locations The engine thermostat is located on the front of the engine (radiator side) in the thermostat housing/engine outlet connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2031 Thermostat: Description and Operation LOCATION The engine thermostat is located on the front of the engine (radiator side) in the thermostat housing/ engine outlet connector. The thermostat has an air bleed (vent) located in the flange and a O-ring for sealing incorporate on it. There is a relief in the thermostat housing/outlet connector for the O-ring. DESIGN The engine cooling thermostats are wax pellet driven, reverse poppet choke type. They are designed to provide the fastest warm up possible by preventing leakage through them and to guarantee a minimum engine operating temperature of 88 - 93°C (192 - 199°F). They also automatically reach wide open so they do not restrict flow to the radiator as temperature of the coolant rises in hot weather to around 104°C (220°F). Above this temperature the coolant temperature is controlled by the radiator, fan, and ambient temperature, not the thermostat. PURPOSE Its primary purpose is to maintain engine temperature in a range that will provide satisfactory engine performance and emission levels under all expected driving conditions. It also provides hot water (coolant) for heater performance. It does this by transferring heat from engine metal and automatic transmission oil cooler (if equipped) to coolant, moving this heated coolant to the heater core and radiator, and then transferring this heat to the ambient air. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2032 Thermostat: Testing and Inspection GENERAL INFORMATION The thermostat is operated by a wax filled container (Pellet) which is sealed so that when heated to a predetermined temperature. The wax expands enough to overcome the closing spring and water pump pressure, which forces the valve to open. Coolant leakage into the pellet will cause a thermostat to fail open. Do not attempt to free up a thermostat with a screwdriver. IMPROPER OPERATION The thermostat that opens too soon type failure mode is included in the on-board diagnosis. The check engine light will not be lit by an open too soon condition. If it has failed open, code 17 will be set. Do not change a thermostat for lack of heater performance or temperature gage position, unless code 17 is present. Thermostat failing shut is the normal long term mode of failure, and normally, only on high mileage vehicles. The temperature gauge will indicate this. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2033 Thermostat: Service and Repair REMOVAL 1. Drain cooling system to the thermostat level or below. 2. Remove Coolant Recovery System (CRS) hose and thermostat/engine outlet connector bolts. 3. Remove thermostat assembly, and clean sealing surfaces. INSTALLATION 1. Place the new thermostat assembly into the engine outlet connector. Align air bleed with notch on the cylinder head. 2. Install thermostat housing/outlet connector onto cylinder head and tighten bolts to 12.5 Nm (110 inch lbs.). Connect the CRS hose. 3. Refill cooling system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Mounting Bolts ..................................................................................................................................... ............................................... 12 Nm (105 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Mounting Bolts ..................................................................................................................................... ............................................... 12 Nm (105 inch lbs.) Inlet Tube To Engine Block .............................. .................................................................................................................................. 12 Nm (105 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2040 Water Pump: Description and Operation GENERAL INFORMATION The water has a diecast aluminum body and housing with a stamped steel impeller. The water pump bolts directly to the block. Cylinder block to water pump sealing is provided by a rubber O-ring. The water pump is driven by the timing belt. The water pump is the heart of the cooling system , pumping the coolant through the engine block, cylinder head, heater core, and radiator. NOTE: The water pump on all models can be replaced without discharging the air conditioning system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2041 Water Pump: Testing and Inspection OPERATIONAL TEST A quick flow test to tell whether or not the pump is working is to see if the heater warms properly. A defective pump will not be able to circulate heated coolant through the long heater hose. Another flow test to help determine pump operation, remove radiator cap. CAUTION: DO NOT remove radiator cap if the cooling system is hot or under pressure. FLOW TEST 1. Remove radiator cap. 2. Remove a small amount of coolant from the system, start the engine and warm up until thermostat opens. With the thermostat open and coolant level low you will see if the water pump is pumping coolant through the system. REASONS FOR REPLACEMENT Replace water pump body assembly if it has any of these defects: Cracks or damage on the body. - Coolant leaks from the shaft seal, evident by coolant traces on the pump body. - Loose or rough turning bearing. - Impeller rubs either the pump body or the engine block. - Impeller loose or damaged. - Sprocket or sprocket flange loose or damaged. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2042 Water Pump: Service and Repair REMOVAL 1. Raise vehicle on a hoist. Remove right inner splash shield. 2. Remove accessory drive belts and power steering pump. 3. Drain cooling system. 4. Support engine from the bottom and remove right engine mount. 5. Remove power steering pump bracket bolts and set pump and bracket assembly aside. Power steering lines do not need to be disconnected. 6. Remove right engine mount bracket. 7. Remove timing belt. 8. Remove inner timing belt cover. 9. Remove water pump attaching screws to engine. INSTALLATION 1. Install O-ring in water pump body O-ring groove. Use small dabs of Mopar Silicone Rubber Adhesive Sealant, or equivalent around the water pump body to secure O-ring in place during installation. CAUTION: Make sure O-ring is properly seated in water pump groove before tightening screws. An improperly located O-ring may cause damage to the O-ring and cause a coolant leak. 2. Assemble pump body to block and tighten screws to 12 Nm (105 inch lbs). Pressurize cooling system to 15 psi with pressure tester and check water pump shaft seal and O-ring for leaks. 3. Rotate pump by hand to check for freedom of movement. 4. Install inner timing belt cover. 5. Install timing belt. 6. Install right engine mount bracket and engine mount. 7. Fill cooling system. 8. Install power steering pump and accessory drive belts. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Description and Operation Catalyst Shield: Description and Operation CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts. PURPOSE The heat shield is needed to protect both the car and the environment from the high temperatures developed in the vicinity of the catalytic converter. CAUTION: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shield on cars. Light over-spray near the edges is permitted. Application of coating will greatly reduce the efficiency of the heat shields resulting in excessive floor pan temperatures and objectionable fumes. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Manifold To Exhaust Pipe .................................................................................................................... .................................................... 27 Nm (20 ft. lbs.) Manifold Flange (LEV) ...................................... ................................................................................................................................. 28 Nm (250 inch lbs.) Mounting Bolts ............................................................................................................................. ....................................................... 23 Nm (200 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2051 Exhaust Manifold: Description and Operation The exhaust manifold is made of nodular cast iron for strength and high temperatures. Exhaust gasses exit through a machined, articulated joint connection to the exhaust pipe. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation Exhaust Manifold: Service and Repair Removal and Installation REMOVAL 1. Remove air cleaner assembly and bracket. 2. Remove exhaust manifold heat shield. 3. Disconnect upstream heated oxygen sensor connector. 4. Remove exhaust pipe from manifold. 5. Remove 8 exhaust manifold retaining fasteners and remove exhaust manifold. NOTE: Discard gasket and clean all gasket surfaces of manifolds and cylinder head. INSTALLATION 1. Set exhaust manifold and gasket in place. Apply Loctite 271 or equivalent to fasteners and tighten to 23 Nm (200 inch lbs.) starting at center and progressing outward in both directions. Repeat this procedure until all fasteners are at specified torque. 2. Install exhaust manifold heat shield. 3. Connect upstream heated oxygen sensor connector. 4. Install air cleaner bracket and assembly. 5. Attach exhaust pipe and tighten fasteners to 28 Nm (250 inch lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 2054 Exhaust Manifold: Service and Repair Cleaning and Inspection 1. Discard gasket and clean all gasket from surfaces of manifolds and cylinder head. 2. Test manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per 300 mm (0.006 inch per foot) of manifold length. 3. Inspect manifolds for cracks or distortion. Replace manifold if necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Removal Exhaust Pipe: Service and Repair Removal 1. Raise vehicle on hoist and apply penetrating oil to band clamp fastener of component being removed. NOTE: Do not use petroleum-based lubricants when removing/installing muffler or exhaust pipe isolators as it may compromise the life of the part. A suitable substitute is a mixture of liquid dish soap and water. 2. Loosen band clamp and remove support insulators at muffler. Remove muffler from exhaust pipe. 3. Disconnect downstream heated oxygen sensor from the catalytic converter pipe. 4. Remove clamp at the catalytic converter to exhaust pipe slip joint. Separate at slip joint. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Removal > Page 2059 5. When removing exhaust pipe, raise rear of vehicle to relieve body weight from rear suspension to provide clearance between pipe and lateral arms. 6. Remove catalytic converter to exhaust manifold attaching bolts. 7. Clean ends of pipes and/or muffler to assure mating of all parts. Discard broken or worn insulators, rusted clamps, supports and attaching parts. NOTE: When replacement is required on any component of the exhaust system, you must use original equipment parts, or equivalent. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Removal > Page 2060 Exhaust Pipe: Service and Repair Installation NOTE: When assembling exhaust system do not tighten clamps until components are aligned and clearances are checked. 1. Assemble catalytic convertor to exhaust manifold ball joint connection. 2. Assemble exhaust pipe to catalytic convertor and the support to the underbody 3. Install the muffler to exhaust pipe and the supports to the underbody. 4. Working from the front of system; 5. Align and tighten the catalytic convertor to exhaust manifold ball joint bolts. 6. Align each component to maintain position and proper clearance with underbody parts and tighten clamps to specification. 7. Connect the downstream heated oxygen sensor. 8. A new style band clamp (Torca) will be used on this vehicles exhaust system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Specifications Exhaust Pipe/Muffler Hanger: Specifications Fastener .............................................................................................................................................. ...................................................... 75 Nm (55 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Removal Exhaust Pipe/Muffler Hanger: Service and Repair Removal 1. Raise vehicle on hoist and apply penetrating oil to band clamp fastener of component being removed. NOTE: Do not use petroleum-based lubricants when removing/installing muffler or exhaust pipe isolators as it may compromise the life of the part. A suitable substitute is a mixture of liquid dish soap and water. 2. Loosen band clamp and remove support insulators at muffler. Remove muffler from exhaust pipe. 3. Clean ends of pipes and/or muffler to assure mating of all parts. Discard broken or worn insulators, rusted clamps, supports and attaching parts. NOTE: When replacement is required on any component of the exhaust system, you must use original equipment parts, or equivalent. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Removal > Page 2066 Exhaust Pipe/Muffler Hanger: Service and Repair Installation NOTE: When assembling exhaust system do not tighten clamps until components are aligned and clearances are checked. 1. Install the muffler to exhaust pipe and the supports to the underbody. 2. Working from the front of system align each component to maintain position and proper clearance with underbody parts and tighten clamps to specification. 3. A new style band clamp (Torca) will be used on this vehicles exhaust system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications Heat Shield: Specifications Manifold Heat Shield ........................................................................................................................... ............................................... 23 Nm (200 inch lbs.) Body Shields .................................................... ....................................................................................................................................... 4 Nm (35 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 2070 Heat Shield: Description and Operation The heat shield is needed to protect both the car and the environment from the high temperatures developed in the vicinity of the catalytic converter. CAUTION: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shield on cars if equipped. Light over-spray near the edges is permitted. Application of coating will greatly reduce the efficiency of the heat shields resulting in excessive floor pan temperatures and objectionable fumes. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Removal Muffler: Service and Repair Removal 1. Raise vehicle on hoist and apply penetrating oil to band clamp fastener of component being removed. NOTE: Do not use petroleum-based lubricants when removing/installing muffler or exhaust pipe isolators as it may compromise the life of the part. A suitable substitute is a mixture of liquid dish soap and water. 2. Loosen band clamp and remove support insulators at muffler. Remove muffler from exhaust pipe. 3. When removing exhaust pipe, raise rear of vehicle to relieve body weight from rear suspension to provide clearance between pipe and lateral arms. 4. Clean ends of pipes and/or muffler to assure mating of all parts. Discard broken or worn insulators, rusted clamps, supports and attaching parts. NOTE: When replacement is required on any component of the exhaust system, you must use original equipment parts, or equivalent. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Removal > Page 2075 Muffler: Service and Repair Installation NOTE: When assembling exhaust system do not tighten clamps until components are aligned and clearances are checked. 1. Install the muffler to exhaust pipe and the supports to the underbody. 2. Working from the front of system; 3. Align and tighten the catalytic convertor to exhaust manifold ball joint bolts. 4. Align each component to maintain position and proper clearance with underbody parts and tighten clamps to specification. 5. A new style band clamp (Torca) will be used on this vehicles exhaust system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Specifications Powertrain Control Module: Specifications PCM 60-Way Connector Torque = 4 Nm (35 in lb) PCM Mounting Screws = 4 Nm (35 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Specifications > Page 2082 Fig. 100 Powertrain Control Module Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2085 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2086 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2087 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2088 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2089 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2090 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2091 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2092 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2093 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2094 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2095 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2096 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2097 Powertrain Control Module: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2098 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2099 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2100 Powertrain Control Module Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2101 Powertrain Control Module: Service Precautions - Before disconnecting any control module, make sure the ignition is off. Failure to do so could damage the module. - When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. - Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. - Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. - Operation of any type, including idling, should be avoided if engine misfiring occurs. Under this condition, the exhaust system operates at abnormally high temperature, which may cause damage to the catalyst or under-body parts of the vehicle. - Alteration or deterioration of ignition or fuel system, or any type of operating condition which results in engine misfiring must be corrected to avoid overheating the catalytic converter. - Proper maintenance and tune-up, according to manufacturer's specifications, should be made to correct abnormal conditions as soon as possible. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation Powertrain Control Module: Description and Operation Circuit Operation CIRCUIT OPERATION Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to cavity 46 of the Powertrain Control Module (PCM). A 20 Amp fuse in the PDC protects circuit A14. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 2104 Powertrain Control Module: Description and Operation PCM Operation Fig. 100 Powertrain Control Module Fig. 3 Data Link Connector The Powertrain Control Module (PCM) is a digital computer containing a microprocessor (Fig. 2). The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. PCM Inputs: Air Conditioning Controls - Battery Voltage - Battery Temperature Sensor - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Fuel Level Sensor - Ignition Switch (A21) - Intake Air Temperature Sensor - Knock Sensor - Manifold Absolute Pressure (MAP) Sensor - Oxygen Sensors - Power Steering Pressure Switch - SCI Receiver - Speed Control Switches - Throttle Position Sensor - Transmission Park/Neutral Switch (Automatic Transmission) - Vehicle Speed Sensor PCM Outputs: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 2105 - Air Conditioning Clutch Relay - Air Conditioning WOT Relay - Auto Shutdown (ASD) Relay - Charging Indicator Lamp - Data Link Connector - Duty Cycle EVAP Canister Purge Solenoid - EGR Solenoid - Fuel Injectors - Fuel Pump Relay - Generator Field - Idle Air Control Motor - Ignition Coils - Malfunction Indicator (Check Engine) Lamp - Radiator Fan Relay - Speed Control Solenoids - Tachometer - Torque Convertor Clutch Solenoid Based on inputs it receives, the PCM adjusts: Fuel Injector Pulse Width - Idle Speed - Ignition Spark Advance - Ignition Coil Dwell - EVAP Canister Purge Operation. The PCM Regulates: Cooling Fan - Air Conditioning - Speed Control System - Generator Charge Rate -- by Adjusting The Generator Field The PCM Also Performs Diagnostics The PCM adjusts injector pulse width (air-fuel ratio) based on: Battery Voltage - Coolant Temperature - Exhaust Gas Content (Oxygen Sensor) - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Manifold Absolute Pressure - Throttle Position The PCM adjusts ignition timing based on: Coolant Temperature - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Knock Sensor - Manifold Absolute Pressure - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) The PCM also adjusts engine idle speed through the idle air control motor based on: Air Conditioning Sense - Battery Temperature - Battery Voltage - Brake Switch - Coolant Temperature - Engine Speed (crankshaft Position Sensor) - Engine Run Time - Manifold Absolute Pressure - Power Steering Pressure Switch - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) - Vehicle Distance (Speed) ASD and Fuel Pump Relay Control Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 2106 The Auto Shutdown (ASD) and fuel pump relays are mounted externally, but turned on and off by the PCM. Crankshaft Position (Engine Speed) Signal The crankshaft position sensor signal is sent to the PCM. If the PCM does not receive the signal within approximately one second of engine cranking, it deactivates the ASD relay and fuel pump relay When these relays deactivate, power is shut off from the fuel injectors, ignition coils, heating element in the oxygen sensors and the fuel pump. PCM Regulated Output Supply Voltages The PCM contains a voltage converter that changes battery voltage to a regulated 8 volts direct current to power: Camshaft Position Sensor - Crankshaft Position Sensor - Vehicle Speed Sensor The PCM also provides a 5 volt direct current supply for: Manifold Absolute Pressure Sensor - Throttle Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 2107 Powertrain Control Module: Description and Operation System Operation SYSTEM OPERATION Powertrain Control Module The speed control electronic control circuitry is integrated into the Powertrain Control Module (PCM). The PCM is located in the engine compartment. The PCM speed control functions are monitored by the On-Board Diagnostics (OBD). All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. The PCM cannot be repaired and must be replaced if faulty. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview Circuit A14 connects to a bus bar in the PDC that the battery feeds. Circuit A14 powers the Automatic Shut Down (ASD) relay and fuel pump relay The A14 circuit also splices to the data link connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Page 2110 Powertrain Control Module: Service and Repair Fig. 100 Powertrain Control Module NOTE: The PCM attaches to the inner fender panel next to the washer fluid bottle on the driver side (Fig. 100). REMOVAL 1. Disconnect negative cable from battery 2. Disconnect positive cable from battery. 3. Remove washer bottle neck. 4. Squeeze tabs on Power Distribution Center (PDC) while pulling PDC up to remove it from bracket. - Lay PDC aside to gain access to PCM bracket screws. 5. Remove screws attaching PCM to body. 3. Lift PCM up and disconnect the 2 40-way connector 7. Remove PCM. INSTALLATION 1. Attach the 2 40-way connector to PCM. 2. Install PCM. Tighten mounting screws to 4 Nm (35 in lb) torque. 3. Install PDC by pushing down into brackets. 4. Install washer bottle neck. 5. Connect positive cable to battery. 6. Connect negative cable to battery. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig. 15 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2114 Power Distribution Center (Top) The relay is located in the Power Distribution Center (PDC). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector Auto Shutdown Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector > Page 2117 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Power Distribution Center (Bottom) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector > Page 2118 Power Distribution Center (Top) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2119 Automatic Shut Down (ASD) Relay: Description and Operation Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. CIRCUIT OPERATION The Automatic Shut Down (ASD) relay is located in the Power Distribution Center (PDC). Power for the coil and contact side of the relay is supplied on circuit A14. This circuit is HOT at all times and protected by a 20 Amp fuse located in the PDC. The Powertrain Control Module (PCM) controls the ground path for the coil side of the relay on circuit K51. This circuit connects to cavity 67 of the PCM. When the PCM supplies the ground path on circuit K51 the contacts in the relay CLOSE connecting circuits A14 and A142. The A142 circuit is spliced and supplies power to the generator, fuel injectors, PCM, ignition coil, and heated oxygen sensors. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 Amp fuse located in the PDC. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 2122 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 2123 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Component Locations Fuel Pump Relay: Component Locations Power Distribution Center (Top) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Component Locations > Page 2129 Fig. 15 Power Distribution Center (PDC) The fuel pump relay is located in the Power Distribution Center (PDC). The inside top of the PDC cover has a label showing relay and fuse location. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Component Locations > Page 2130 Fuel Pump Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Fuel Pump Relay Connector Fuel Pump Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Fuel Pump Relay Connector > Page 2133 Fuel Pump Relay: Diagrams Power Distribution Power Distribution Center (Bottom) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Fuel Pump Relay Connector > Page 2134 Power Distribution Center (Top) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Fuel Pump Relay Operation Fuel Pump Relay: Description and Operation Fuel Pump Relay Operation NAME OF CODE: Fuel Pump Relay Control Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the fuel pump relay control circuit. THEORY OF OPERATION: The fuel pump relay controls the 12-volt source to the fuel pump. If the vehicle is equipped with a power distribution center, the relay is located in the Power Distribution Center (PDC). One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the RUN or CRANK position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the fuel pump relay control circuit ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Fuel pump relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Fuel Pump Relay Operation > Page 2137 Fuel Pump Relay: Description and Operation Fuel Pump Relay Control Circuit Trouble Code Name of Code: Fuel Pump Relay Control Circuit When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: An open or shorted condition is detected in the fuel pump relay control circuit. Theory of Operation: The fuel pump relay controls the 12-volt source to the fuel pump. If the vehicle is equipped with a power distribution center, the relay is located in the PDC. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "run position". The circuit is completed when the other side of the relay coil is grounded by the powertrain control module. The PCM grounds the relay when the ignition switch is in either the run or crank position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the fuel pump relay control circuit ground. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - Fuel pump relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Page 2138 Fuel Pump Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30 is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85 -- The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86 supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A -- When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87 When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Page 2139 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig. 15 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2143 Power Distribution Center (Top) The relay is located in the Power Distribution Center (PDC). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector Auto Shutdown Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector > Page 2146 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Power Distribution Center (Bottom) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector > Page 2147 Power Distribution Center (Top) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2148 Automatic Shut Down (ASD) Relay: Description and Operation Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. CIRCUIT OPERATION The Automatic Shut Down (ASD) relay is located in the Power Distribution Center (PDC). Power for the coil and contact side of the relay is supplied on circuit A14. This circuit is HOT at all times and protected by a 20 Amp fuse located in the PDC. The Powertrain Control Module (PCM) controls the ground path for the coil side of the relay on circuit K51. This circuit connects to cavity 67 of the PCM. When the PCM supplies the ground path on circuit K51 the contacts in the relay CLOSE connecting circuits A14 and A142. The A142 circuit is spliced and supplies power to the generator, fuel injectors, PCM, ignition coil, and heated oxygen sensors. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 Amp fuse located in the PDC. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 2151 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 2152 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Service Precautions Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Service Precautions > Page 2158 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature. This temperature data, along with data from monitored line voltage, is used by the (PCM) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Battery Temperature Sensor The sensor is located forward of the vehicle battery, and is attached to the battery tray. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to Powertrain Management/Computer and Controls/Testing and Inspection. 1. The sensor is located under the battery and is attached to the battery tray. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25 °C (75-80 °F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) Ohms should be observed. 5. If reading is above or below the specification, replace the sensor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 2161 Battery Temperature Sensor: Service and Repair REMOVE 1. Make sure ignition switch is in OFF position and all accessories are OFF. Disconnect Battery Negative Cable 2. Remove battery negative cable first then the positive cable. Battery Thermoguard 3. Remove battery thermoguard. WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN. Air Inlet Tube Pull Strap Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 2162 4. Remove temperature sensor mounting nut from battery tray. Battery Temperature Sensor Connector 5. Disconnect sensor wire connector. INSTALL - For installation reverse above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis > Page 2167 Camshaft Position Sensor: Technical Service Bulletins Cam/Crank Sensor - No Start Diagnostics NO: 18-24-97 GROUP: Vehicle Performance DATE: Aug. 8, 1997 SUBJECT: No Start Diagnostics Cam/Crank Sensor $01 and $28 MODELS: 1997 (FJ) Avenger/Sebring/Talon 1997 (GS) Chrysler Voyager (International Market) 1997 (JA) Breeze/Cirrus/Stratus 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1997 (NS) Town & Country/Caravan/Voyager 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L DOHC/SOHC (NATURALLY ASPIRATED), 2.4L, 3.3L, 3.5L, OR 3.8L ENGINE. DISCUSSION: If a vehicle exhibits a no-start due to failure of the cam or crank sensor, the opposite sensor may be reported as the DTC (i.e. bad cam sensor sets crank sensor DTC and vice versa). The faulty sensor may generate a signal strong enough (at key "ON") to be interpreted by the controller as a legitimate signal. Since the engine is not running, the opposite sensor will not be generating any pulses. The controller, expecting corresponding pulses from both sensors, matures a fault for the sensor that is not generating any pulses. In this case, the good sensor is reported as faulty. To verify which sensor is at fault, use the DRB III and select DRB III Standalone, 1994 - 1998 Diagnostics, select Engine system, select Monitor Display, and No Start monitor. Under the No Start monitor the cam and crank sensors should display a no response or LOST on the display. If a sensor is reporting a signal at key ON", it should be replaced. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2170 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2171 Camshaft Position Sensor: Locations Camshaft Position Sensor Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2172 Camshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2173 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity OPERATION The camshaft position sensor attaches to the rear of the cylinder head. A target magnet attaches to the rear of the camshaft and indexes to the Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2174 correct position. The target magnet has four different poles arranged in an asymmetrical pattern (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the camshaft position sensor The K7 circuit connects to cavity 44 of the PCM connector. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 33 of the PCM connector. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing Camshaft Position Sensor: Testing and Inspection Component Testing The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting an oscilloscope and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing > Page 2177 Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing > Page 2178 Camshaft Position Sensor: Testing and Inspection Failure to Start Test Fig.20 Ignition Coil Engine Harness Connector This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Sensor Replacement Camshaft Position Sensor Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head. REMOVAL 1. Remove filtered air tube from the throttle body and air cleaner housing. 2. Disconnect electrical connector from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.35 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft (Fig. 35). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 2181 Fig.36 Target Magnet Installation NOTE: The target magnet has locating dowels that fit into machined locating holes in the end of the camshaft (Fig. 36). INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install filtered air tube. Tighten clamps to 3 Nm ±1 (25 in lb ±5) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 2182 Camshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 18 Nm (165 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2186 Engine Coolant Temperature Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2187 Engine Coolant Temperature Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2188 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig.13 Engine Coolant Temperature Sensor-DOHC PURPOSE The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. - The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. OPERATION As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The coolant sensor threads into the intake manifold next to the thermostat housing (Fig. 13). New sensors have sealant applied to the threads. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. The sensor also operates the engine cool and temperature gauge in the instrument cluster on circuit G20. See: Engine, Cooling and Exhaust/Cooling System/Lamps and Indicators Cooling System/Temperature Gauge/Description and Operation From circuit K2 the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes causing a change in current draw. The K2 circuit connects to cavity 26 of the PCM connector. The PCM provides ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig. 80 Engine Coolant Temperature Sensor Location-DOHC 1. With the key off, disconnect wire harness connector from coolant temperature sensor (Fig. 80). Fig. 27 Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 27). The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 28 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing > Page 2191 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Helpful Information The engine coolant temperature sensor is case grounded. The case ground provides the ground for the coolant temperature gauge circuit G20. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 2192 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig.39 Engine Coolant Temperature Sensor-DOHC NOTE: The engine coolant temperature sensor threads into the rear of the cylinder head. New sensors have sealant applied to the threads. REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. - Tighten to 18 Nm (165 in lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Cam/Crank Sensor - No Start Diagnostics Crankshaft Position Sensor: Technical Service Bulletins Cam/Crank Sensor - No Start Diagnostics NO: 18-24-97 GROUP: Vehicle Performance DATE: Aug. 8, 1997 SUBJECT: No Start Diagnostics Cam/Crank Sensor $01 and $28 MODELS: 1997 (FJ) Avenger/Sebring/Talon 1997 (GS) Chrysler Voyager (International Market) 1997 (JA) Breeze/Cirrus/Stratus 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1997 (NS) Town & Country/Caravan/Voyager 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L DOHC/SOHC (NATURALLY ASPIRATED), 2.4L, 3.3L, 3.5L, OR 3.8L ENGINE. DISCUSSION: If a vehicle exhibits a no-start due to failure of the cam or crank sensor, the opposite sensor may be reported as the DTC (i.e. bad cam sensor sets crank sensor DTC and vice versa). The faulty sensor may generate a signal strong enough (at key "ON") to be interpreted by the controller as a legitimate signal. Since the engine is not running, the opposite sensor will not be generating any pulses. The controller, expecting corresponding pulses from both sensors, matures a fault for the sensor that is not generating any pulses. In this case, the good sensor is reported as faulty. To verify which sensor is at fault, use the DRB III and select DRB III Standalone, 1994 - 1998 Diagnostics, select Engine system, select Monitor Display, and No Start monitor. Under the No Start monitor the cam and crank sensors should display a no response or LOST on the display. If a sensor is reporting a signal at key ON", it should be replaced. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2199 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position Sensor Bolts ........................................................................................................ .......................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2200 Fig 7 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2201 Crankshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2202 Crankshaft Position Sensor: Description and Operation Fig 7 Crankshaft Position Sensor Fig. 14 Timing Reference Notches Fig.6 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60° signature notch (Fig. 14). The notches generate pulses from high to low in the crankshaft position sensor output voltage. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2203 - When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69° before top dead center (BTDC). - The second notch represents 49° BTDC. - The third notch represents 29°. - The last notch in each set represents 9° before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM connector. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test Fig.20 Ignition Coil Engine Harness Connector This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 2206 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig 7 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Crankshaft Position Sensor Bolts torque ....................................................................................................................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2209 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > General Description Fuel Level Sensor: Description and Operation General Description Fig. 10 Level Sensor Diagnosis OPERATION The fuel gauge sending unit is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and two variable resistors (tracks). These two tracks are used to send two different electrical signals. One is used for fuel gauge operation and the other is for OBD II emission requirements. Track 1 fuel gauge operation: As the fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge on the instrument panel to read full. As the fuel level decreases, the float and arm move down. This increases the sending unit resistance, causing the fuel gauge on the instrument panel to read empty Track 2-OBD II emission requirements: A variable voltage signal is sent to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes if the fuel level in the tank is less than 15 percent of its rated capacity. CIRCUIT OPERATION Circuit G4 provides an input to the Powertrain Control Module (PCM) indicating fuel tank level. This circuit connects to cavity 23 of the PCM connector. The G4 circuit is also used for the fuel gauge located in the instrument cluster. For operation of fuel gauge, See: Instrument Panel, Gauges and Warning Indicators/Fuel Gauge/Description and Operation Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > General Description > Page 2214 Fuel Level Sensor: Description and Operation Related Trouble Codes and Set Conditions Fuel Level Sending Unit Volts Too High Name of Code: Fuel Level Sending Unit Volts Too High When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes above a calculated value. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel systems monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Open sensor signal circuit - Fuel level sending unit failure - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Fuel Level Sending Unit Volts Too Low Name of Code: Fuel Level Sending Unit Volts Too Low When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes below 0.10 volts. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel system monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Sensor signal circuit shorted to ground - Fuel level sending unit failure - Loss of fuel ignition switch output voltage - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Sending Unit Operation Check Fuel Level Sensor: Testing and Inspection Sending Unit Operation Check When a problem occurs with a cluster gauge check for a defective sending unit or wiring. Do this before disassembling the cluster. 1. Sending units and wiring can be checked by grounding the connector leads at the sending unit in the vehicle. 2. With the ignition in the ON position, a grounded input will cause the fuel or temperature gauge to read at or above maximum. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 2217 Fuel Level Sensor: Testing and Inspection Sending Unit Voltage Check Fig. 1 Fuel Guage Test Terminal 1. Remove the fuel gauge electrical harness. 2. Connect 12 volt test light to the fuel gauge and ground terminal. 3. Turn ignition to On position and proceed as follows: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 2218 a. If test light illuminates and pointer of gauge does not swing, replace fuel gauge. b. If test light illuminates and pointer of gauge swings, replace fuel gauge unit. c. If test light does not light and pointer of gauge does not swing, check the electrical harness for kinks chaffing and broken wires. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 2219 Fuel Level Sensor: Testing and Inspection Sending Unit Resistance Check Fig. 10 Level Sensor Diagnosis This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. To test the level sensor, connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector. Move the float lever to the positions shown in the resistance chart. Record the resistance at each point. Replace the level sensor if the resistance is not within specifications. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Page 2220 Fuel Level Sensor: Service and Repair Fig. 21 Fuel Pump/Level Sensor Electrical Connector NOTE: Remove fuel pump module prior to beginning this procedure. REMOVAL 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector. Fig. 22 Wire Terminal Locking Wedge 2. Pull off blue locking wedge. Fig. 23 Wire Terminal Locking Finger 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Page 2221 Fig. 24 Removing Wires From Connector 4. Push level sensor signal and ground terminals out of the connector. Fig. 25 Loosening Level Sensor 5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Fig. 26 Level Sensor Removal/Installation 6. Push level sensor down slightly. - Ensure tab at bottom of sensor locks in place. 7. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 8. Install locking wedge on connector. 9. Push connector up into bottom of fuel pump module electrical connector. 10. Install fuel pump module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications MAP Sensor Torque Aluminum Manifold = 3 Nm (30 in lbs) Plastic Manifold = 2 Nm (20 in lbs) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2225 Map/Intake Air Temperature Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2226 Intake Air Temperature Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2227 Intake Air Temperature Sensor: Description and Operation Fig.15 MAP/IAT Sensor-DOHC PURPOSE The intake air temperature sensor measures the temperature of the air as it enters the engine. The sensor supplies one of the inputs the PCM uses to determine injector pulse-width. CONSTRUCTION The MAP/Intake Air Temperature (IAT) sensor, located on the intake manifold, combines the MAP and Intake Air Temperature (IAT) functions into one sensor. CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. Circuit K21 connects to cavity 37 of the PCM connector. From circuit K21 the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor As intake air temperature changes the resistance in the sensor changes causing a change in current draw. The PCM provides ground for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Intake Air Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 2230 Intake Air Temperature Sensor: Service and Repair Map/Intake Air Temperature Sensor Fig. 98 MAP/IAT Sensor-DOHC NOTE: The MAP/IAT sensor attaches to the intake manifold plenum (Fig. 98). Fig. 97 Air Inlet Duct-DOHC REMOVAL 1. Remove air inlet duct wing nut and duct from intake manifold (Fig. 97). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 2231 2. Disconnect the electrical connector from the MAP/IAT sensor. 3. Remove sensor mounting screws. 4. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seals. 2. Tighten mounting screws to 2 Nm (20 in lb) torque for a plastic manifold and 3 Nm (30 in lb) for a aluminum manifold. 3. Attach electrical connector to sensor 4. Install air inlet duct wing nut and duct from intake manifold, insure that the duct does not interfer with ignition cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2235 Knock Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2236 Knock Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2237 Knock Sensor: Description and Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 24 of the PCM connector. The PCM provides ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Helpful Information Knock Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2240 Knock Sensor: Testing and Inspection Component Testing The knock sensor can be tested with a digital voltmeter. Sensor output should be between 80 mV and 4 volts with the engine running between 576 and 2,208 rpm. If the output falls outside of this range a DTC will be set. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Page 2241 Knock Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications Manifold Pressure/Vacuum Sensor: Electrical Specifications The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications > Page 2246 Manifold Pressure/Vacuum Sensor: Mechanical Specifications MAP Sensor Torque Aluminum Manifold = 3 Nm (30 in lbs) Plastic Manifold = 2 Nm (20 in lbs) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2247 Map Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2248 IAT/Map Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2249 Manifold Pressure/Vacuum Sensor: Description and Operation Fig.15 MAP/IAT Sensor-DOHC OPERATION The PCM supplies 5 volts to the MAP sen son The MAP sensor function converts intake manifold pressure into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP sensor voltage decreases proportionately. Also, as vacuum decreases, MAP sensor voltage increases proportionately. During cranking, before the engine starts running, the PCM determines atmosphenc air pressure from the MAP sensor voltage. While the engine operates, the PCM determines intake manifold pressure from the MAP sensor voltage. Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and the air/fuel mixture. The MAP/Intake Air Temperature Sensor (MAP/IAT) sensor mounts to the intake manifold. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Manifold Absolute Pressure (MAP) sensor. Circuit K6 connects to cavity 61 of the PCM connector. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity 36 of the PCM connector. The PCM provides ground for the MAP sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing Manifold Pressure/Vacuum Sensor: Testing and Inspection Component Testing Fig. 82 MAP Sensor Connector CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 1 and 4 (Fig. 82). With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. If OK, go to next step. - If not OK, go to step 3. 2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness condition. Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 43. - If OK, go to next step. - If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 3 and 1 with the key ON. The voltage should be approximately 5 volts ± 0.5V). Five volts (± 0.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor. - If not OK, repair or replace the wire harness as required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing > Page 2252 Manifold Pressure/Vacuum Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 2253 Manifold Pressure/Vacuum Sensor: Service and Repair Map/Intake Air Temperature Sensor Fig. 98 MAP/IAT Sensor-DOHC NOTE: The MAP/IAT sensor attaches to the intake manifold plenum (Fig. 98). Fig. 97 Air Inlet Duct-DOHC REMOVAL 1. Remove air inlet duct wing nut and duct from intake manifold (Fig. 97). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 2254 2. Disconnect the electrical connector from the MAP/IAT sensor. 3. Remove sensor mounting screws. 4. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seals. 2. Tighten mounting screws to 2 Nm (20 in lb) torque for a plastic manifold and 3 Nm (30 in lb) for a aluminum manifold. 3. Attach electrical connector to sensor 4. Install air inlet duct wing nut and duct from intake manifold, insure that the duct does not interfer with ignition cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Upstream and Downstream Heated Oxygen Sensors Torque = 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2260 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2261 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2262 Downstream Oxygen Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2263 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2264 Oxygen Sensor: Description and Operation CIRCUIT OPERATION Circuit A14 is a bus bar in the Power Distribution Center (PDC), and connects to battery voltage. The contact side of the Automatic Shut Down (ASD) relay connects circuit A14 and circuit A142. A 20 Amp fuse in the PDC protects circuits A14 and A142. Circuit A14 also supplies voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) controls the ground path circuit for the coil side of the ASD relay on circuit K51. Circuit K51 connects to cavity 67 of the PCM connector. Circuit A142 splices to supply voltage for the upstream and downstream heated oxygen sensors. The A142 circuit also splices to cavity 6 of the PCM. The input provided by circuit A142 at cavity 6 tells the PCM that the ASD relay energized. Circuit K41 delivers the signal from the upstream heated oxygen sensor to the PCM. Circuit K41 connects to cavity 30 of the PCM connector. Circuit K141 delivers the signal from the down-stream heated oxygen sensor to the PCM. Circuit K141 connects to cavity 51 of the PCM connector. The PCM provides a ground for the upstream and downstream heated oxygen sensor signals (circuit K41 and K141) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector Circuit Z1 provides ground for the heater circuits in each sensor. Circuit Z1 terminates at the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information Oxygen Sensor: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, ASD relay, generator, and the upstream and downstream heated oxygen sensors. The PCM controls the ground circuit for each of the components powered by circuit A142. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2267 Oxygen Sensor: Testing and Inspection Oxygen Sensor Heater Circuit Test NOTE: Use an ohmmeter to test the heating element of the oxygen sensors. 1. Disconnect the electrical connector from each oxygen sensor. - The white wires in the sensor connector are the power and ground circuits for the heater elements. 2. Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. - Replace the heated oxygen sensor if the resistance is not between 4 and 7 ohms. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor Oxygen Sensor: Service and Repair Downstream O2 Sensor Fig. 19 Downstream Heated Oxygen Sensor NOTE: The downstream heated oxygen sensor threads into the exhaust pipe behind the catalytic convertor (Fig. 19). REMOVAL 1. Raise vehicle. 2. Disconnect electrical connector from sensor. 3. Disconnect sensor electrical harness from clips along body. Fig. 20 Downstream Heated Oxygen Sensor Removal/Installation 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 20). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 2270 Oxygen Sensor: Service and Repair Upstream O2 Sensor Fig. 18 Upstream Heated Oxygen Sensor Removal/Installation REMOVAL 1. Raise and support vehicle. 2. Unplug sensor connector. 3. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 18). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 2271 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 2276 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2277 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2278 Power Steering Pressure Switch: Description and Operation Fig. 15 Power Steering Pressure Switch PURPOSE On vehicles equipped with power steering, a power steering pressure switch is used to improve the vehicle's idle quality. The pressure switch improves vehicle idle quality, by controlling engine idle speed when required. The switch (Fig. 15) provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. OPERATION The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed is increased. This increase in engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. When power steering pump pressure exceeds 2,758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. The power steering pressure switch is mounted directly to the power steering gear on vehicles requiring its usage. CIRCUIT OPERATION The power steering pressure switch opens and closes circuit K10 between the Powertrain Control Module (PCM) and ground. Circuit K10 connects to cavity 45 of the PCM connector. Circuit Z12 provides ground for the power steering pressure switch. The grounding point for circuit Z12 is the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2279 Power Steering Pressure Switch: Service and Repair CAUTION: When removing and installing the power steering pressure switch, the use of a 7/8 inch deep well socket is required. The deep well socket will prevent damage to the plastic, electrical connector area, of the power steering pressure switch. REMOVE 1. Disconnect negative battery cable from the negative post of the battery. Be sure cable is isolated from negative post on battery. 2. Raise vehicle. 3. Locate power steering pressure switch on back side of power steering gear. 4. Remove vehicle wiring harness connector, from power steering pressure switch. 5. Remove power steering pressure switch, from power steering gear. CAUTION: When tightening the power steering pressure switch after installation in steering gear, do not exceed the torque specification shown in step 1 below. Over-tightening may result in stripping the threads out of the pressure switch port on the steering gear. INSTALL 1. Install power steering pressure switch into power steering gear by hand until fully seated. Then torque power steering pressure switch to 8 Nm (70 inch lbs.). 2. Install vehicle wiring harness connector onto power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with locking tab on power steering pressure switch. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar (R), Power Steering Fluid, or equivalent. 3. Fill power steering reservoir to correct fluid level. 4. Connect negative cable back on negative post of battery. 5. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2284 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2285 Throttle Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2286 Throttle Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2287 Throttle Position Sensor: Description and Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS mounts to the throttle body and connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- from 0.38 to 1.03 volts. - AT Wide open throttle -- 3.1 to 4.0 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). CIRCUIT OPERATION From the Powertrain Control Module (PCM) circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2290 Throttle Position Sensor: Testing and Inspection Component Testing To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool and follow the appropriate procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for correct pinout. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2291 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2292 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (20 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Throttle Position Sensor Mounting Screws 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2296 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2297 Transmission Position Switch/Sensor: Description and Operation Fig. 20 Park/Neutral Switch OPERATION On vehicles with 3-speed automatic transmission the park/neutral switch provides an input to the Powertrain Control Module (PCM). The park/neutral position switch is located on the automatic transaxle housing Fig. 20. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. CIRCUIT OPERATION When CLOSED the Transmission Range Switch (TRS) provides an input to the Powertrain Control Module (PCM) on circuit T41. This circuit connects to cavity 76 of the PCM connector. The T41 circuit is spliced and provides a ground path for the engine starter relay, and the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Mounting Bolt 2.2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 2301 Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2304 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2305 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2306 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2307 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2308 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2309 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2310 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2311 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2312 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2313 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2314 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2315 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2316 Vehicle Speed Sensor: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2317 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2318 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2319 Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > System Operation Vehicle Speed Sensor: Description and Operation System Operation SYSTEM OPERATION The Vehicle Speed Sensor (VSS) is a pulse generator mounted to an adapter near the transmission output shaft. The sensor is driven through the adapter by a speedometer pinion gear. The VSS pulse signal to the speedometer/odometer is monitored by the PCM speed control circuitry to determine vehicle speed and to maintain speed control set speed. Refer to the Powertrain Management/Computer and Control Systems/Diagnostic Procedures for diagnosis and testing of this component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > System Operation > Page 2322 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor-PCM Input Fig. 17 Vehicle Speed Sensor -- Automatic Transmission Fig. 18 Vehicle Speed Sensor -- Manual Transmission PURPOSE The sensor input is used by the PCM to determine vehicle speed and distance traveled. OPERATION The vehicle speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a closed throttle signal from the throttle position sensor, indicate a closed throttle deceleration to the PCM. Under deceleration conditions, the PCM adjusts the Idle Air Control (IAC) motor to maintain a desired MAP value. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. The vehicle speed sensor signal is also used to operate: Speedometer - Speed control - Daytime Running Lights (Canadian Vehicles only). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the Vehicle Speed Sensor (VSS). The K7 circuit connects to cavity 44 of the PCM connector. Circuit G7 from the VSS provides an input signal to the PCM. The G7 circuit connects to cavity 66 of the PCM connector. The PCM provides ground for the VSS signal (circuit G7) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Helpful Information Vehicle Speed Sensor: Testing and Inspection Helpful Information Circuit G7 splices to the speedometer and odometer in the instrument cluster. Circuit K7 splices to supply 8 Volts to the camshaft position sensor and crankshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 2325 Vehicle Speed Sensor: Service and Repair Fig. 24 Vehicle Speed Sensor Fig. 7 Vehicle Speed Sensor And Connector Fig. 8 Vehicle Speed Sensor And Speedometer Pinion Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 2326 NOTE: The vehicle speed sensor is located in the transmission extension housing (Fig. 24). REMOVAL 1. Disconnect electrical connector from sensor. 2. Remove the sensor mounting bolt. 3. Lift the sensor out of the transaxle extension housing. Ensure the 0-ring was removed with the sensor. NOTE: The speed sensor gear meshes with a gear on the output shaft. INSTALLATION 1. With 0-ring in place, install sensor and seat sensor by hand -- to ensure proper gear engagement. 2. Install mounting bolt and torque bolt to 2.2 Nm (20 in lb). 3. Connect electrical connector to sensor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2332 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2333 Throttle Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2334 Throttle Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2335 Throttle Position Sensor: Description and Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS mounts to the throttle body and connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- from 0.38 to 1.03 volts. - AT Wide open throttle -- 3.1 to 4.0 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). CIRCUIT OPERATION From the Powertrain Control Module (PCM) circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2338 Throttle Position Sensor: Testing and Inspection Component Testing To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool and follow the appropriate procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for correct pinout. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2339 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2340 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (20 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis > Page 2346 Camshaft Position Sensor: Technical Service Bulletins Cam/Crank Sensor - No Start Diagnostics NO: 18-24-97 GROUP: Vehicle Performance DATE: Aug. 8, 1997 SUBJECT: No Start Diagnostics Cam/Crank Sensor $01 and $28 MODELS: 1997 (FJ) Avenger/Sebring/Talon 1997 (GS) Chrysler Voyager (International Market) 1997 (JA) Breeze/Cirrus/Stratus 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1997 (NS) Town & Country/Caravan/Voyager 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L DOHC/SOHC (NATURALLY ASPIRATED), 2.4L, 3.3L, 3.5L, OR 3.8L ENGINE. DISCUSSION: If a vehicle exhibits a no-start due to failure of the cam or crank sensor, the opposite sensor may be reported as the DTC (i.e. bad cam sensor sets crank sensor DTC and vice versa). The faulty sensor may generate a signal strong enough (at key "ON") to be interpreted by the controller as a legitimate signal. Since the engine is not running, the opposite sensor will not be generating any pulses. The controller, expecting corresponding pulses from both sensors, matures a fault for the sensor that is not generating any pulses. In this case, the good sensor is reported as faulty. To verify which sensor is at fault, use the DRB III and select DRB III Standalone, 1994 - 1998 Diagnostics, select Engine system, select Monitor Display, and No Start monitor. Under the No Start monitor the cam and crank sensors should display a no response or LOST on the display. If a sensor is reporting a signal at key ON", it should be replaced. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2349 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2350 Camshaft Position Sensor: Locations Camshaft Position Sensor Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2351 Camshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2352 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity OPERATION The camshaft position sensor attaches to the rear of the cylinder head. A target magnet attaches to the rear of the camshaft and indexes to the Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2353 correct position. The target magnet has four different poles arranged in an asymmetrical pattern (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the camshaft position sensor The K7 circuit connects to cavity 44 of the PCM connector. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 33 of the PCM connector. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing Camshaft Position Sensor: Testing and Inspection Component Testing The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting an oscilloscope and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing > Page 2356 Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing > Page 2357 Camshaft Position Sensor: Testing and Inspection Failure to Start Test Fig.20 Ignition Coil Engine Harness Connector This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Sensor Replacement Camshaft Position Sensor Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head. REMOVAL 1. Remove filtered air tube from the throttle body and air cleaner housing. 2. Disconnect electrical connector from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.35 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft (Fig. 35). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 2360 Fig.36 Target Magnet Installation NOTE: The target magnet has locating dowels that fit into machined locating holes in the end of the camshaft (Fig. 36). INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install filtered air tube. Tighten clamps to 3 Nm ±1 (25 in lb ±5) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 2361 Camshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Cam/Crank Sensor - No Start Diagnostics Crankshaft Position Sensor: Technical Service Bulletins Cam/Crank Sensor - No Start Diagnostics NO: 18-24-97 GROUP: Vehicle Performance DATE: Aug. 8, 1997 SUBJECT: No Start Diagnostics Cam/Crank Sensor $01 and $28 MODELS: 1997 (FJ) Avenger/Sebring/Talon 1997 (GS) Chrysler Voyager (International Market) 1997 (JA) Breeze/Cirrus/Stratus 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1997 (NS) Town & Country/Caravan/Voyager 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L DOHC/SOHC (NATURALLY ASPIRATED), 2.4L, 3.3L, 3.5L, OR 3.8L ENGINE. DISCUSSION: If a vehicle exhibits a no-start due to failure of the cam or crank sensor, the opposite sensor may be reported as the DTC (i.e. bad cam sensor sets crank sensor DTC and vice versa). The faulty sensor may generate a signal strong enough (at key "ON") to be interpreted by the controller as a legitimate signal. Since the engine is not running, the opposite sensor will not be generating any pulses. The controller, expecting corresponding pulses from both sensors, matures a fault for the sensor that is not generating any pulses. In this case, the good sensor is reported as faulty. To verify which sensor is at fault, use the DRB III and select DRB III Standalone, 1994 - 1998 Diagnostics, select Engine system, select Monitor Display, and No Start monitor. Under the No Start monitor the cam and crank sensors should display a no response or LOST on the display. If a sensor is reporting a signal at key ON", it should be replaced. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2368 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position Sensor Bolts ........................................................................................................ .......................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2369 Fig 7 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2370 Crankshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2371 Crankshaft Position Sensor: Description and Operation Fig 7 Crankshaft Position Sensor Fig. 14 Timing Reference Notches Fig.6 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60° signature notch (Fig. 14). The notches generate pulses from high to low in the crankshaft position sensor output voltage. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2372 - When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69° before top dead center (BTDC). - The second notch represents 49° BTDC. - The third notch represents 29°. - The last notch in each set represents 9° before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM connector. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test Fig.20 Ignition Coil Engine Harness Connector This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 2375 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig 7 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Crankshaft Position Sensor Bolts torque ....................................................................................................................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2378 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation SYSTEM OPERATION Ignition Lock Cylinder Detents The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detents: - Accessory - Off (lock) - Unlock - On/Run - Start Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 2383 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Detentes The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detentes: Accessory - Off (lock) - Unlock - On/Run - Start REMOVAL 1. Disconnect negative cable from battery. 2. Place key cylinder in RUN position. - Through the hole in the lower shroud, depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. - Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. - To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. - Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Connect negative cable to battery Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 2387 Knock Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 2388 Knock Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 2389 Knock Sensor: Description and Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 24 of the PCM connector. The PCM provides ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Helpful Information Knock Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2392 Knock Sensor: Testing and Inspection Component Testing The knock sensor can be tested with a digital voltmeter. Sensor output should be between 80 mV and 4 volts with the engine running between 576 and 2,208 rpm. If the output falls outside of this range a DTC will be set. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Page 2393 Knock Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Typical -- SOHC Shown Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle Odometer <= 1,000 Miles ................................................................................ ............................................................................................. 550 - 1,300 rpm Odometer >= 1,000 Miles .................................................................................................................................................... ......................... 600 - 1,300 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2402 Idle Speed: Testing and Inspection Fig. 31 PCV Vacuum Nipple 1. Turn ignition key off. 2. Disconnect the PCV valve hose from the intake manifold nipple (Fig. 31). Cap the PCV vacuum nipple. Fig. 32 Purge Hose 3. Disconnect purge hose from the nipple on the throttle body (Fig. 32). Fig. 33 Orifice 6457 Attached To Purge Nipple 4. Use a piece of hose to attach Air Metering Orifice 6457 (0.125 in. orifice) or equivalent, to the purge nipple on the throttle body (Fig. 33). 5. Ensure that all accessories are off. 6. Connect the DRB or equivalent scan tool to the data link connector inside the passenger compartment. 7. Run engine in Park or Neutral until the cooling fan has cycled on and off at least once (180°F). 8. Using the DRB or equivalent scan tool, access Minimum Airflow Idle Speed. 9. The following will then occur: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2403 - Idle air control motor will fully close - Idle spark advance will become fixed - PCM will go open loop enriched - DRB or equivalent scan tool displays engine RPM 10. If idle RPM is within the range shown below, throttle body minimum airflow is set correctly. Odometer Reading Idle RPM Below 1,000 Miles 550 - 1,300 RPM Above 1,000 Miles 600 - 1,300 RPM 11. If idle RPM is above specifications, use the DRB or equivalent scan tool to check idle air control motor operation. If idle air control motor is OK, replace throttle body. If idle air flow is below specification, shut off the engine and clean the throttle body as follows: a. Remove the throttle body from engine. WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves, do not let Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash thoroughly after using cleaner. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when is closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 14. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 12. Shut off engine. 13. Remove Air Metering Orifice 6457 or equivalent. Install purge hose. 14. Remove cap from PCV valve. Connect hose to PCV valve. 15. Remove DRB or equivalent scan tool. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Fig. 104 Air Intake Duct Fig. 105 Removal/Installation of Air Inlet Duct NOTE: Neon vehicles do not use a heated air inlet system. The PCM adjusts fuel injector pulse width and ignition timing to compensate for different ambient temperatures. NOTE: The air cleaner attaches to a bracket on the rear of the cylinder head. An ambient air duct supplies underhood air for the engine. REMOVAL 1. Remove air intake tube (Fig. 104) from air cleaner and intake manifold (Fig. 105). Fig. 106 Removal/Installation Air Cleaner Front Housing and Element 2. Tighten clasps on top of air cleaner housing. Rotate front of housing forward then lift front away from air cleaner housing (Fig 106). 3. Remove air cleaner element from front housing (Fig. 106). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2408 INSTALLATION 1. Install air cleaner element into front housing. 2. Rotate front of housing forward then lower into place and locate tabs in slots. - Fasten clasps on top of air cleaner housing. - Install air intake duct at air cleaner and intake manifold. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2413 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 12 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) 6. Replace Pressure test port cap when finished releasing pressure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Cable Routing and Firing Order Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Cable Routing and Firing Order Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum Cables #1 & #4 3,050 Ohms 4,250 Ohms Cables #2 & #3 2,300 Ohms 3,300 Ohms Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2424 Ignition Cable: Description and Operation NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Plastic clips in various locations protect the cables from damage. When the cables are replaced the clips must be used to prevent damage to the cables. The #1 cable must be routed under the PCV hose and clipped to the #2 cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Ignition Cable: Initial Inspection and Diagnostic Overview Fig. 3 Spark Plug Cables NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Be sure that the plastic clip on PCV hose is positioned so that cable clip is beneath hose, and that #1 cable is snapped into this clip to protect it from metal PCV clamp. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2427 Ignition Cable: Component Tests and General Diagnostics Testing For Open Circuits, High Resistance and Loose Terminals Use an ohmmeter to check cables for opens, loose terminals or high resistance as follows: 1. Remove cable from spark plug. 2. Remove cable from the coil tower. 3. Connect the ohmmeter between the spark plug end terminal and the coil end terminal. - Make sure ohmmeter probes are in good contact. - Resistance should be within tolerance shown in the cable resistance chart. - If resistance is not within tolerance, replace cable assembly. Test all spark plug cables in the same manner. - If no problems are found, SEE Ignition System/System Diagnosis/Testing For Spark At Coil. SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum Cables #1 & #4 3,050 Ohms 4,250 Ohms Cables #2 & #3 2,300 Ohms 3,300 Ohms Testing For Punctures and Cracks When testing cables for punctures and cracks with an oscilloscope and an inductive voltage probe, follow the instructions of the equipment manufacturers. CAUTION: Do not leave any one spark plug cable disconnected for more than 30 seconds during test or possible heat damage to catalytic converter will occur. If an oscilloscope and inductive probe are not available, cables can be tested as follows: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. WARNING: The ignition system generates approximately 40,000 volts. Personal injury could result from contact with this system. 2. With the engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). - If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. - Replace cracked, leaking or faulty cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning Ignition Cable: Service and Repair Cleaning Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning > Page 2430 Ignition Cable: Service and Repair Replacement Fig. 3 Spark Plug Cables NOTE: The cables insulate the spark plugs and cover the top of the spark plug tube (Fig. 3). CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. REMOVAL 1. Remove spark plug cable from coil first. Lightly grasp the top of the cable. 2. Rotate the insulator 1/2 turn and pull straight up in a steady motion. 3. To replace the cables, disconnect the cable from the ignition coil. INSTALLATION Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube.Then connect the other end to coil pack. Be sure that the plastic clip on PCV hose is positioned so that cable clip is beneath hose, and that #1 cable is snapped into this clip to protect it from metal PCV clamp. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... .......................................................... (0.033-0.038 in) Torque ............................................................ ............................................................................................................................................... 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2434 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ....................................................................... RC9YC Thread Size .................................................... ................................................................................................................................................. (14mm) 3/4 in. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2435 Spark Plug: Description and Operation Resistor spark plugs are used in this engine. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for spark plug diagnosis. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2438 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear - Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2439 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2440 Spark Plug: Testing and Inspection Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2441 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear - Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2442 clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Heavy Colored Deposits DESCRIPTION: Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on the side facing the intake valve. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap, and reinstall .............................................................................................................................................................. .................................................................................... Normal Operating Conditions NORMAL OPERATING CONDITIONS Normal Operation And Cold(Carbon) Fouling The few deposits present will be probably light tan or slightly gray in color with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 1600 km (1000 miles) of operation for non Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2443 platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, have the electrodes filed and regapped, and then reinstalled. CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum spark plugs. This would damage the platinum pads which would shorten spark plug life. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit. The rust color deposits can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Oil or Ash Encrusted OIL OR ASH ENCRUSTED Oil Or Ash Encrusted If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of spark plugs. Ash encrusted spark plugs can be cleaned and reused. Premature Electrode Wear - Preignition Damage PREIGNITION DAMAGE Preignition Damage Excessive combustion chamber temperature can cause preignition damage. First, the center electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Other possible causes include ignition timing over-advanced and incorrect spark plug heat range. Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2444 center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Determine if the spark plugs are the correct type, as specified on the VECI label, or if other operating conditions are causing engine overheating. Red, Brown, Yellow or White Deposits - Fuel Additives SCAVENGER DEPOSITS Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed using standard procedures. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and reused. Shiny Yellow Glaze COMBUSTION DEPOSITS A shiny yellow glaze coating on the spark plug insulator is evidence of metallic by-products of fuel combustion, caused by chemical additives in certain fuels. Avoid sudden acceleration with wide open throttle after long periods of low speed driving. Spark plugs with combustion deposits can be cleaned and reused. Spark Plug Inspection - Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance Schedules. - Spark plugs that have low mileage may be cleaned and reused if not otherwise defective -- SEE Spark Plug Condition. After cleaning, file the center electrode flat with a small point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The spark plug gap is 0.033 to0.038 in. - Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Wet Oily Deposits FUEL FOULING A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air and reinstall them in the engine. White or Gray - Burned or Blistered Insulator SPARK PLUG OVERHEATING Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2445 Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in. per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug overheating. Also check for lean air-fuel mixture. Check the torque value of the plugs to ensure good plug-engine seat contact. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 2446 Spark Plug: Adjustments Setting Spark Plug Electrode Gap Fig.2 Setting Spark Plug Electrode Gap Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground -- center electrode. Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap .............................................................................................................................................. ............................................. 0.033 to 0.038 in Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 2447 Spark Plug: Service and Repair CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. CAUTION: Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion. SPARK PLUG REMOVAL 1. Remove the spark plug using a quality socket with a rubber or foam insert. 2. Inspect the spark plug condition. SPARK PLUG CLEANING Spark plugs that have low mileage may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. SPARK PLUG INSTALLATION 1. To avoid cross threading, start the spark plug into the cylinder head by hand. 2. Tighten spark plugs to 28 Nm (20 ft lb) torque. 3. Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube. 4. Connect coil. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications COMPRESSION PRESSURE (at 250 - 400 RPM): Standard .............................................................................................................................................. ............................ 1172 - 1551 kPa (170 - 225 psi) Minimum ............................................................. ................................................................................................................................... 689 kPa (100 psi) COMPRESSION PRESSURE DIFFERENCE OF ALL CYLINDER: Maximum ............................................................................................................................................. ....................................................................... 25% VACUUM: Manifold ............................................................................................................................................... .......................................... 60 kPa (18 inches Hg) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2451 Compression Check: Testing and Inspection PROCEDURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire (Conventional Ignition System). For Direct Ignition System (DIS) disconnect the coil connector. 5 . Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adaptor into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is reached on gage. Record this pressure as #1 cylinder pressure. 7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 9. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. 11. Clean or replace spark plugs as necessary and adjust gap. Tighten to specifications. 12. Test resistance of spark plug cables. Perform secondary circuit inspection. 13. Test coil output voltage, primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at idle and different RPM ranges. 15. The air filter elements should be replaced as specified. 16. Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt drives. 18. Road test vehicle as a final test. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates this engine is equipped with hydraulic lifters or lash adjusters and therefore does not require adjustment. See "Rocker Arm: Service and Repair" for further information. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Locations Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation > A/C Clutch Relay Operation A/C Signal: Description and Operation A/C Clutch Relay Operation Theory of Operation: The A/C compressor clutch relay controls the 12 volt source for the A/C clutch. The relay is located in the power distribution center. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the run position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). When A/C is requested, the PCM adjusts the idle speed to accommodate the A/C compressor load on the engine. The PCM grounds the relay control circuit after the PCM receives an A/C request and adjustment of the idle speed has been implemented. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation > A/C Clutch Relay Operation > Page 2461 A/C Signal: Description and Operation Related Trouble Codes and Set Conditions Name of Code: A/C Clutch Relay Circuit When Monitored: With the ignition key in the run position and battery voltage above 10 volts. Set Condition: An open or shorted condition is detected in the A/C clutch relay control circuit. Theory of Operation: The A/C compressor clutch relay controls the 12 volt source for the A/C clutch. The relay is located in the power distribution center. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the run position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). When A/C is requested, the PCM adjusts the idle speed to accommodate the A/C compressor load on the engine. The PCM grounds the relay control circuit after the PCM receives an A/C request and adjustment of the idle speed has been implemented. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - Compressor clutch relay control circuit open or shorted - Inoperative circuit driver in powertrain control module Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications MAP Sensor Torque Aluminum Manifold = 3 Nm (30 in lbs) Plastic Manifold = 2 Nm (20 in lbs) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2465 Map/Intake Air Temperature Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2466 Intake Air Temperature Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2467 Intake Air Temperature Sensor: Description and Operation Fig.15 MAP/IAT Sensor-DOHC PURPOSE The intake air temperature sensor measures the temperature of the air as it enters the engine. The sensor supplies one of the inputs the PCM uses to determine injector pulse-width. CONSTRUCTION The MAP/Intake Air Temperature (IAT) sensor, located on the intake manifold, combines the MAP and Intake Air Temperature (IAT) functions into one sensor. CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. Circuit K21 connects to cavity 37 of the PCM connector. From circuit K21 the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor As intake air temperature changes the resistance in the sensor changes causing a change in current draw. The PCM provides ground for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Intake Air Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 2470 Intake Air Temperature Sensor: Service and Repair Map/Intake Air Temperature Sensor Fig. 98 MAP/IAT Sensor-DOHC NOTE: The MAP/IAT sensor attaches to the intake manifold plenum (Fig. 98). Fig. 97 Air Inlet Duct-DOHC REMOVAL 1. Remove air inlet duct wing nut and duct from intake manifold (Fig. 97). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 2471 2. Disconnect the electrical connector from the MAP/IAT sensor. 3. Remove sensor mounting screws. 4. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seals. 2. Tighten mounting screws to 2 Nm (20 in lb) torque for a plastic manifold and 3 Nm (30 in lb) for a aluminum manifold. 3. Attach electrical connector to sensor 4. Install air inlet duct wing nut and duct from intake manifold, insure that the duct does not interfer with ignition cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Service Precautions Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Service Precautions > Page 2475 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature. This temperature data, along with data from monitored line voltage, is used by the (PCM) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Battery Temperature Sensor The sensor is located forward of the vehicle battery, and is attached to the battery tray. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to Powertrain Management/Computer and Controls/Testing and Inspection. 1. The sensor is located under the battery and is attached to the battery tray. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25 °C (75-80 °F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) Ohms should be observed. 5. If reading is above or below the specification, replace the sensor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 2478 Battery Temperature Sensor: Service and Repair REMOVE 1. Make sure ignition switch is in OFF position and all accessories are OFF. Disconnect Battery Negative Cable 2. Remove battery negative cable first then the positive cable. Battery Thermoguard 3. Remove battery thermoguard. WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN. Air Inlet Tube Pull Strap Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 2479 4. Remove temperature sensor mounting nut from battery tray. Battery Temperature Sensor Connector 5. Disconnect sensor wire connector. INSTALL - For installation reverse above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Description and Operation > Component Description Brake Signal: Description and Operation Component Description PURPOSE When the brake switch is activated, the PCM receives an input indicating that the brakes are being applied. The brake switch is mounted on the brake pedal support bracket. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Description and Operation > Component Description > Page 2485 Brake Signal: Description and Operation Brake Switch Sense Circuit Name of Code: Brake (Stop Lamp) Switch Sense Circuit When Monitored: With engine running. Set Condition: Decel (30 - 0 mph). The PCM monitors the brake switch signal expecting it to be continuously low while the vehicle speed cycles 16 times. The count is reset to zero whenever the brake switch indicates a high signal. Accel (0 - 20 mph): The PCM monitors the brake switch signal expecting it to be high while the following maneuver occurs 16 times. After the vehicle speed increases, the PCM must accumulate 6 seconds while delta throttle voltage is above 0.02 volts. The count is reset to zero whenever the brake switch indicates a low signal. Theory of Operation: The brake switch signal is used to disable speed control by venting the Speed Control (S/C) servo. The brake switch signal is used to disable (3 speed ATX) the part throttle unlock, as well as disabling the vehicle speed sensor diagnostics. The signal from the brake switch is used to enable OBDII purge monitor. It also modifies the stall torque management control. Possible Causes: - Brake switch failure - Switch alignment - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis > Page 2490 Camshaft Position Sensor: Technical Service Bulletins Cam/Crank Sensor - No Start Diagnostics NO: 18-24-97 GROUP: Vehicle Performance DATE: Aug. 8, 1997 SUBJECT: No Start Diagnostics Cam/Crank Sensor $01 and $28 MODELS: 1997 (FJ) Avenger/Sebring/Talon 1997 (GS) Chrysler Voyager (International Market) 1997 (JA) Breeze/Cirrus/Stratus 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1997 (NS) Town & Country/Caravan/Voyager 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L DOHC/SOHC (NATURALLY ASPIRATED), 2.4L, 3.3L, 3.5L, OR 3.8L ENGINE. DISCUSSION: If a vehicle exhibits a no-start due to failure of the cam or crank sensor, the opposite sensor may be reported as the DTC (i.e. bad cam sensor sets crank sensor DTC and vice versa). The faulty sensor may generate a signal strong enough (at key "ON") to be interpreted by the controller as a legitimate signal. Since the engine is not running, the opposite sensor will not be generating any pulses. The controller, expecting corresponding pulses from both sensors, matures a fault for the sensor that is not generating any pulses. In this case, the good sensor is reported as faulty. To verify which sensor is at fault, use the DRB III and select DRB III Standalone, 1994 - 1998 Diagnostics, select Engine system, select Monitor Display, and No Start monitor. Under the No Start monitor the cam and crank sensors should display a no response or LOST on the display. If a sensor is reporting a signal at key ON", it should be replaced. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2493 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2494 Camshaft Position Sensor: Locations Camshaft Position Sensor Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2495 Camshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2496 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity OPERATION The camshaft position sensor attaches to the rear of the cylinder head. A target magnet attaches to the rear of the camshaft and indexes to the Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2497 correct position. The target magnet has four different poles arranged in an asymmetrical pattern (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the camshaft position sensor The K7 circuit connects to cavity 44 of the PCM connector. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 33 of the PCM connector. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing Camshaft Position Sensor: Testing and Inspection Component Testing The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting an oscilloscope and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing > Page 2500 Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing > Page 2501 Camshaft Position Sensor: Testing and Inspection Failure to Start Test Fig.20 Ignition Coil Engine Harness Connector This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Sensor Replacement Camshaft Position Sensor Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head. REMOVAL 1. Remove filtered air tube from the throttle body and air cleaner housing. 2. Disconnect electrical connector from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.35 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft (Fig. 35). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 2504 Fig.36 Target Magnet Installation NOTE: The target magnet has locating dowels that fit into machined locating holes in the end of the camshaft (Fig. 36). INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install filtered air tube. Tighten clamps to 3 Nm ±1 (25 in lb ±5) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 2505 Camshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 18 Nm (165 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2509 Engine Coolant Temperature Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2510 Engine Coolant Temperature Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2511 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig.13 Engine Coolant Temperature Sensor-DOHC PURPOSE The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. - The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. OPERATION As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The coolant sensor threads into the intake manifold next to the thermostat housing (Fig. 13). New sensors have sealant applied to the threads. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. The sensor also operates the engine cool and temperature gauge in the instrument cluster on circuit G20. See: Engine, Cooling and Exhaust/Cooling System/Lamps and Indicators Cooling System/Temperature Gauge/Description and Operation From circuit K2 the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes causing a change in current draw. The K2 circuit connects to cavity 26 of the PCM connector. The PCM provides ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig. 80 Engine Coolant Temperature Sensor Location-DOHC 1. With the key off, disconnect wire harness connector from coolant temperature sensor (Fig. 80). Fig. 27 Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 27). The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 28 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing > Page 2514 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Helpful Information The engine coolant temperature sensor is case grounded. The case ground provides the ground for the coolant temperature gauge circuit G20. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 2515 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig.39 Engine Coolant Temperature Sensor-DOHC NOTE: The engine coolant temperature sensor threads into the rear of the cylinder head. New sensors have sealant applied to the threads. REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. - Tighten to 18 Nm (165 in lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Cam/Crank Sensor - No Start Diagnostics Crankshaft Position Sensor: Technical Service Bulletins Cam/Crank Sensor - No Start Diagnostics NO: 18-24-97 GROUP: Vehicle Performance DATE: Aug. 8, 1997 SUBJECT: No Start Diagnostics Cam/Crank Sensor $01 and $28 MODELS: 1997 (FJ) Avenger/Sebring/Talon 1997 (GS) Chrysler Voyager (International Market) 1997 (JA) Breeze/Cirrus/Stratus 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1997 (NS) Town & Country/Caravan/Voyager 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L DOHC/SOHC (NATURALLY ASPIRATED), 2.4L, 3.3L, 3.5L, OR 3.8L ENGINE. DISCUSSION: If a vehicle exhibits a no-start due to failure of the cam or crank sensor, the opposite sensor may be reported as the DTC (i.e. bad cam sensor sets crank sensor DTC and vice versa). The faulty sensor may generate a signal strong enough (at key "ON") to be interpreted by the controller as a legitimate signal. Since the engine is not running, the opposite sensor will not be generating any pulses. The controller, expecting corresponding pulses from both sensors, matures a fault for the sensor that is not generating any pulses. In this case, the good sensor is reported as faulty. To verify which sensor is at fault, use the DRB III and select DRB III Standalone, 1994 - 1998 Diagnostics, select Engine system, select Monitor Display, and No Start monitor. Under the No Start monitor the cam and crank sensors should display a no response or LOST on the display. If a sensor is reporting a signal at key ON", it should be replaced. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2522 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position Sensor Bolts ........................................................................................................ .......................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2523 Fig 7 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2524 Crankshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2525 Crankshaft Position Sensor: Description and Operation Fig 7 Crankshaft Position Sensor Fig. 14 Timing Reference Notches Fig.6 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60° signature notch (Fig. 14). The notches generate pulses from high to low in the crankshaft position sensor output voltage. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2526 - When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69° before top dead center (BTDC). - The second notch represents 49° BTDC. - The third notch represents 29°. - The last notch in each set represents 9° before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM connector. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test Fig.20 Ignition Coil Engine Harness Connector This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 2529 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig 7 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Crankshaft Position Sensor Bolts torque ....................................................................................................................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2532 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations Fig. 3 Data Link Connector Data Link Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2538 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2539 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2540 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2541 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2542 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2543 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2544 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2545 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2546 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2547 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2548 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2549 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2550 Data Link Connector: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2551 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2552 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2553 Data Link Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 2554 Data Link Connector: Description and Operation Fig. 3 Data Link Connector PURPOSE Communication link to Powertrain Control Module (PCM) Technician can access inputs and memory including: - Sensor input values - Diagnostic Trouble Codes (DTC's) stored in memory - Last deactivation cause (i.e.. speed control last shut off by; speed control switch, brake switch or no crank sensor signal). Technician can actuate most PCM output devices. NOTE: Monitoring inputs, reading memory -- other than codes -- and actuating output devices can only be accomplished through the use of a scan tool. SEE Computers and Control System/Testing and Inspection. CIRCUIT OPERATION Circuit A14 supplies battery voltage to the universal data link connector. Circuit A14 originates in the Power Distribution Center (PDC) and connects to a battery fed bus bar. A 20 Amp fuse protects circuit A14. A twisted pair of wires, circuits D1 and D2, from the Airbag Control Module (ACM) connect to the universal data link connector. Ground circuit Z12 splices to two cavities of the data link connector. The Z12 circuit also connects to cavities 10 and 50 of the PCM connector. Circuit D20 connects to cavity 75 of the PCM and to the universal data link connector. Circuit D20 is the SCI receive circuit for the PCM. Circuit D21 connects to cavity 65 of the PCM and to the universal data link connector. Circuit D21 is the SCI transmit circuit for the PCM. The D21 circuit splices to the ABS module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Testing and Inspection > Helpful Information Data Link Connector: Testing and Inspection Helpful Information The grounding point for circuit Z12 is the left side of the radiator closure panel. Circuit Z12 also supplies ground for the PCM high current drivers and has the same termination point as circuit Z11. If the system loses ground for the ganged circuits at the left side radiator closure panel the vehicle will not operate. Check the connection at the ganged ground circuit eyelet. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Description and Operation EGR Backpressure Transducer: Description and Operation Fig. 1 EGR System Fig. 2 Electronic EGR Transducer (EET) The electronic EGR transducer (EET) contains an electrically operated solenoid and a back-pressure transducer (Fig. 2). The Powertrain Control Module (PCM) operates the solenoid. Exhaust system back-pressure controls the transducer. When exhaust system back-pressure becomes high enough, it fully closes a bleed valve in the transducer. - When the PCM de-energizes the solenoid and back-pressure closes the transducer bleed valve, vacuum flows through the transducer to operate the EGR valve. De-energizing the solenoid, but not fully closing the transducer bleed hole (because of low back-pressure), varies the strength of vacuum applied to the EGR valve. Varying the strength of the vacuum changes the amount of EGR supplied to the engine. This provides the correct amount of exhaust gas recirculation for different operating conditions. This system does not allow EGR at idle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Description and Operation > Page 2560 EGR Backpressure Transducer: Service and Repair Fig. 1 EGR System NOTE: If the EGR system operates incorrectly, replace the entire EGR valve and transducer together. The EGR valve and Electronic EGR Transducer (EET) are calibrated together. NOTE: The EGR valve and EET attach to the rear of the cylinder head (Fig. 1). REMOVAL 1. Disconnect vacuum supply tube from EET solenoid. 2. Disconnect electrical connector from solenoid. 3. Remove EGR tube to EGR valve screws. 4. Remove EGR valve mounting screws. Remove EGR valve and transducer. 5. Clean gasket surfaces. Discard old gaskets. If necessary, clean EGR passages. INSTALLATION 1. Loosely install EGR valve with new gaskets. 2. Finger tighten EGR tube fasteners. 3. Tighten EGR tube fasteners to 11 Nm (95 in lb) torque. 4. Tightening EGR valve mounting screws to 22 Nm (200 in lb) torque. 5. Connect vacuum supply tube to solenoid. 6. Attach electrical connector to solenoid. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Specifications Powertrain Control Module: Specifications PCM 60-Way Connector Torque = 4 Nm (35 in lb) PCM Mounting Screws = 4 Nm (35 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Specifications > Page 2564 Fig. 100 Powertrain Control Module Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2567 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2568 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2569 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2570 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2571 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2572 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2573 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2574 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2575 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2576 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2577 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2578 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2579 Powertrain Control Module: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2580 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2581 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2582 Powertrain Control Module Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2583 Powertrain Control Module: Service Precautions - Before disconnecting any control module, make sure the ignition is off. Failure to do so could damage the module. - When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. - Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. - Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. - Operation of any type, including idling, should be avoided if engine misfiring occurs. Under this condition, the exhaust system operates at abnormally high temperature, which may cause damage to the catalyst or under-body parts of the vehicle. - Alteration or deterioration of ignition or fuel system, or any type of operating condition which results in engine misfiring must be corrected to avoid overheating the catalytic converter. - Proper maintenance and tune-up, according to manufacturer's specifications, should be made to correct abnormal conditions as soon as possible. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation Powertrain Control Module: Description and Operation Circuit Operation CIRCUIT OPERATION Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to cavity 46 of the Powertrain Control Module (PCM). A 20 Amp fuse in the PDC protects circuit A14. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 2586 Powertrain Control Module: Description and Operation PCM Operation Fig. 100 Powertrain Control Module Fig. 3 Data Link Connector The Powertrain Control Module (PCM) is a digital computer containing a microprocessor (Fig. 2). The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. PCM Inputs: Air Conditioning Controls - Battery Voltage - Battery Temperature Sensor - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Fuel Level Sensor - Ignition Switch (A21) - Intake Air Temperature Sensor - Knock Sensor - Manifold Absolute Pressure (MAP) Sensor - Oxygen Sensors - Power Steering Pressure Switch - SCI Receiver - Speed Control Switches - Throttle Position Sensor - Transmission Park/Neutral Switch (Automatic Transmission) - Vehicle Speed Sensor PCM Outputs: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 2587 - Air Conditioning Clutch Relay - Air Conditioning WOT Relay - Auto Shutdown (ASD) Relay - Charging Indicator Lamp - Data Link Connector - Duty Cycle EVAP Canister Purge Solenoid - EGR Solenoid - Fuel Injectors - Fuel Pump Relay - Generator Field - Idle Air Control Motor - Ignition Coils - Malfunction Indicator (Check Engine) Lamp - Radiator Fan Relay - Speed Control Solenoids - Tachometer - Torque Convertor Clutch Solenoid Based on inputs it receives, the PCM adjusts: Fuel Injector Pulse Width - Idle Speed - Ignition Spark Advance - Ignition Coil Dwell - EVAP Canister Purge Operation. The PCM Regulates: Cooling Fan - Air Conditioning - Speed Control System - Generator Charge Rate -- by Adjusting The Generator Field The PCM Also Performs Diagnostics The PCM adjusts injector pulse width (air-fuel ratio) based on: Battery Voltage - Coolant Temperature - Exhaust Gas Content (Oxygen Sensor) - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Manifold Absolute Pressure - Throttle Position The PCM adjusts ignition timing based on: Coolant Temperature - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Knock Sensor - Manifold Absolute Pressure - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) The PCM also adjusts engine idle speed through the idle air control motor based on: Air Conditioning Sense - Battery Temperature - Battery Voltage - Brake Switch - Coolant Temperature - Engine Speed (crankshaft Position Sensor) - Engine Run Time - Manifold Absolute Pressure - Power Steering Pressure Switch - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) - Vehicle Distance (Speed) ASD and Fuel Pump Relay Control Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 2588 The Auto Shutdown (ASD) and fuel pump relays are mounted externally, but turned on and off by the PCM. Crankshaft Position (Engine Speed) Signal The crankshaft position sensor signal is sent to the PCM. If the PCM does not receive the signal within approximately one second of engine cranking, it deactivates the ASD relay and fuel pump relay When these relays deactivate, power is shut off from the fuel injectors, ignition coils, heating element in the oxygen sensors and the fuel pump. PCM Regulated Output Supply Voltages The PCM contains a voltage converter that changes battery voltage to a regulated 8 volts direct current to power: Camshaft Position Sensor - Crankshaft Position Sensor - Vehicle Speed Sensor The PCM also provides a 5 volt direct current supply for: Manifold Absolute Pressure Sensor - Throttle Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 2589 Powertrain Control Module: Description and Operation System Operation SYSTEM OPERATION Powertrain Control Module The speed control electronic control circuitry is integrated into the Powertrain Control Module (PCM). The PCM is located in the engine compartment. The PCM speed control functions are monitored by the On-Board Diagnostics (OBD). All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. The PCM cannot be repaired and must be replaced if faulty. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview Circuit A14 connects to a bus bar in the PDC that the battery feeds. Circuit A14 powers the Automatic Shut Down (ASD) relay and fuel pump relay The A14 circuit also splices to the data link connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Page 2592 Powertrain Control Module: Service and Repair Fig. 100 Powertrain Control Module NOTE: The PCM attaches to the inner fender panel next to the washer fluid bottle on the driver side (Fig. 100). REMOVAL 1. Disconnect negative cable from battery 2. Disconnect positive cable from battery. 3. Remove washer bottle neck. 4. Squeeze tabs on Power Distribution Center (PDC) while pulling PDC up to remove it from bracket. - Lay PDC aside to gain access to PCM bracket screws. 5. Remove screws attaching PCM to body. 3. Lift PCM up and disconnect the 2 40-way connector 7. Remove PCM. INSTALLATION 1. Attach the 2 40-way connector to PCM. 2. Install PCM. Tighten mounting screws to 4 Nm (35 in lb) torque. 3. Install PDC by pushing down into brackets. 4. Install washer bottle neck. 5. Connect positive cable to battery. 6. Connect negative cable to battery. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > General Description Fuel Level Sensor: Description and Operation General Description Fig. 10 Level Sensor Diagnosis OPERATION The fuel gauge sending unit is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and two variable resistors (tracks). These two tracks are used to send two different electrical signals. One is used for fuel gauge operation and the other is for OBD II emission requirements. Track 1 fuel gauge operation: As the fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge on the instrument panel to read full. As the fuel level decreases, the float and arm move down. This increases the sending unit resistance, causing the fuel gauge on the instrument panel to read empty Track 2-OBD II emission requirements: A variable voltage signal is sent to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes if the fuel level in the tank is less than 15 percent of its rated capacity. CIRCUIT OPERATION Circuit G4 provides an input to the Powertrain Control Module (PCM) indicating fuel tank level. This circuit connects to cavity 23 of the PCM connector. The G4 circuit is also used for the fuel gauge located in the instrument cluster. For operation of fuel gauge, See: Instrument Panel, Gauges and Warning Indicators/Fuel Gauge/Description and Operation Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > General Description > Page 2597 Fuel Level Sensor: Description and Operation Related Trouble Codes and Set Conditions Fuel Level Sending Unit Volts Too High Name of Code: Fuel Level Sending Unit Volts Too High When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes above a calculated value. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel systems monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Open sensor signal circuit - Fuel level sending unit failure - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Fuel Level Sending Unit Volts Too Low Name of Code: Fuel Level Sending Unit Volts Too Low When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes below 0.10 volts. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel system monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Sensor signal circuit shorted to ground - Fuel level sending unit failure - Loss of fuel ignition switch output voltage - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Sending Unit Operation Check Fuel Level Sensor: Testing and Inspection Sending Unit Operation Check When a problem occurs with a cluster gauge check for a defective sending unit or wiring. Do this before disassembling the cluster. 1. Sending units and wiring can be checked by grounding the connector leads at the sending unit in the vehicle. 2. With the ignition in the ON position, a grounded input will cause the fuel or temperature gauge to read at or above maximum. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 2600 Fuel Level Sensor: Testing and Inspection Sending Unit Voltage Check Fig. 1 Fuel Guage Test Terminal 1. Remove the fuel gauge electrical harness. 2. Connect 12 volt test light to the fuel gauge and ground terminal. 3. Turn ignition to On position and proceed as follows: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 2601 a. If test light illuminates and pointer of gauge does not swing, replace fuel gauge. b. If test light illuminates and pointer of gauge swings, replace fuel gauge unit. c. If test light does not light and pointer of gauge does not swing, check the electrical harness for kinks chaffing and broken wires. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 2602 Fuel Level Sensor: Testing and Inspection Sending Unit Resistance Check Fig. 10 Level Sensor Diagnosis This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. To test the level sensor, connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector. Move the float lever to the positions shown in the resistance chart. Record the resistance at each point. Replace the level sensor if the resistance is not within specifications. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Page 2603 Fuel Level Sensor: Service and Repair Fig. 21 Fuel Pump/Level Sensor Electrical Connector NOTE: Remove fuel pump module prior to beginning this procedure. REMOVAL 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector. Fig. 22 Wire Terminal Locking Wedge 2. Pull off blue locking wedge. Fig. 23 Wire Terminal Locking Finger 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Page 2604 Fig. 24 Removing Wires From Connector 4. Push level sensor signal and ground terminals out of the connector. Fig. 25 Loosening Level Sensor 5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Fig. 26 Level Sensor Removal/Installation 6. Push level sensor down slightly. - Ensure tab at bottom of sensor locks in place. 7. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 8. Install locking wedge on connector. 9. Push connector up into bottom of fuel pump module electrical connector. 10. Install fuel pump module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications IAC Motor-To-Throttle Body Bolts 7 Nm (60 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2608 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2609 Idle Air Control Motor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2610 Idle Speed/Throttle Actuator - Electronic: Description and Operation THEORY OF OPERATION: The idle air control (IAC) motor is used by the Powertrain Control Module (PCM) to help regulate idle speed. The motor controls the amount of air allowed to bypass the throttle blade. The PCM controls the motor using four driver circuits to position the stepper motor. CIRCUIT OPERATION The Powertrain Control Module (PCM) operates the Idle Air Control (IAC) motor through 4 circuits K39, K40, K59, and K60. Each circuit connects to separate cavities in the PCM connector. Circuit K39 connects to cavity 57 of the PCM connector. - Circuit K40 connects to cavity 48 of the PCM connector. - Circuit K59 connects to cavity 58 of the PCM connector. - Circuit K60 connects to cavity 49 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2611 Idle Speed/Throttle Actuator - Electronic: Service and Repair Fig. 95 Servicing Idle Air Control Motor CAUTION: When servicing throttle body components, always reassemble components with new 0-rings and seals where applicable. Never use lubricants on 0-rings or seals, damage may result. If assembly of component is difficult, use water to aid assembly. Use care when removing hoses to prevent damage to hose or hose nipple. REMOVAL 1. Disconnect negative cable from battery 2. Remove electrical connector from idle air control motor and throttle position sensor. 3. Remove the EVAP purge hose from the throttle body. 4. Remove throttle body. 5. Remove idle air control motor mounting screws (Fig. 95). 6. Remove motor from throttle body Ensure the 0-ring is removed with the motor. INSTALLATION 1. The new idle air control motor has a new 0-ring installed on it. - If pintle measures more than 1 inch (25 mm) it must be retracted. - Use the DRB Idle Air Control Motor Open/Close Test to retract the pintle (battery must be connected). 2. Carefully place idle air control motor into throttle body 3. Install mounting screws. Tighten screws to 7 Nm (60 in lb) torque. 4. Install throttle body. 5. Connect electrical connector to idle air control motor and throttle position sensor. 6. Connect the EVAP purge hose to the throttle body nipple. 7. Connect negative cable to battery. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2616 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2617 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2618 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2619 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2620 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2621 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2622 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2623 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2624 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2625 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2626 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2627 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2628 Information Bus: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2629 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2630 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2631 Vehicle Communication System Schematic Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2635 Knock Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2636 Knock Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2637 Knock Sensor: Description and Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 24 of the PCM connector. The PCM provides ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Helpful Information Knock Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2640 Knock Sensor: Testing and Inspection Component Testing The knock sensor can be tested with a digital voltmeter. Sensor output should be between 80 mV and 4 volts with the engine running between 576 and 2,208 rpm. If the output falls outside of this range a DTC will be set. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Page 2641 Knock Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig. 15 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2645 Power Distribution Center (Top) The relay is located in the Power Distribution Center (PDC). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector Auto Shutdown Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector > Page 2648 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Power Distribution Center (Bottom) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector > Page 2649 Power Distribution Center (Top) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2650 Automatic Shut Down (ASD) Relay: Description and Operation Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. CIRCUIT OPERATION The Automatic Shut Down (ASD) relay is located in the Power Distribution Center (PDC). Power for the coil and contact side of the relay is supplied on circuit A14. This circuit is HOT at all times and protected by a 20 Amp fuse located in the PDC. The Powertrain Control Module (PCM) controls the ground path for the coil side of the relay on circuit K51. This circuit connects to cavity 67 of the PCM. When the PCM supplies the ground path on circuit K51 the contacts in the relay CLOSE connecting circuits A14 and A142. The A142 circuit is spliced and supplies power to the generator, fuel injectors, PCM, ignition coil, and heated oxygen sensors. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 Amp fuse located in the PDC. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 2653 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 2654 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation CIRCUIT OPERATION The Service Engine Soon lamp illuminates when the ignition switch is in the ON position and prior to starting the vehicle. The lamp will turn off after the vehicle is started. If while the vehicle is running a problem is detected in the engine control system the lamp is illuminated. This is accomplished by the Powertrain Control Module (PCM) grounding the G3 circuit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications Manifold Pressure/Vacuum Sensor: Electrical Specifications The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications > Page 2662 Manifold Pressure/Vacuum Sensor: Mechanical Specifications MAP Sensor Torque Aluminum Manifold = 3 Nm (30 in lbs) Plastic Manifold = 2 Nm (20 in lbs) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2663 Map Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2664 IAT/Map Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2665 Manifold Pressure/Vacuum Sensor: Description and Operation Fig.15 MAP/IAT Sensor-DOHC OPERATION The PCM supplies 5 volts to the MAP sen son The MAP sensor function converts intake manifold pressure into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP sensor voltage decreases proportionately. Also, as vacuum decreases, MAP sensor voltage increases proportionately. During cranking, before the engine starts running, the PCM determines atmosphenc air pressure from the MAP sensor voltage. While the engine operates, the PCM determines intake manifold pressure from the MAP sensor voltage. Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and the air/fuel mixture. The MAP/Intake Air Temperature Sensor (MAP/IAT) sensor mounts to the intake manifold. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Manifold Absolute Pressure (MAP) sensor. Circuit K6 connects to cavity 61 of the PCM connector. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity 36 of the PCM connector. The PCM provides ground for the MAP sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing Manifold Pressure/Vacuum Sensor: Testing and Inspection Component Testing Fig. 82 MAP Sensor Connector CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 1 and 4 (Fig. 82). With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. If OK, go to next step. - If not OK, go to step 3. 2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness condition. Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 43. - If OK, go to next step. - If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 3 and 1 with the key ON. The voltage should be approximately 5 volts ± 0.5V). Five volts (± 0.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor. - If not OK, repair or replace the wire harness as required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing > Page 2668 Manifold Pressure/Vacuum Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 2669 Manifold Pressure/Vacuum Sensor: Service and Repair Map/Intake Air Temperature Sensor Fig. 98 MAP/IAT Sensor-DOHC NOTE: The MAP/IAT sensor attaches to the intake manifold plenum (Fig. 98). Fig. 97 Air Inlet Duct-DOHC REMOVAL 1. Remove air inlet duct wing nut and duct from intake manifold (Fig. 97). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 2670 2. Disconnect the electrical connector from the MAP/IAT sensor. 3. Remove sensor mounting screws. 4. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seals. 2. Tighten mounting screws to 2 Nm (20 in lb) torque for a plastic manifold and 3 Nm (30 in lb) for a aluminum manifold. 3. Attach electrical connector to sensor 4. Install air inlet duct wing nut and duct from intake manifold, insure that the duct does not interfer with ignition cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Upstream and Downstream Heated Oxygen Sensors Torque = 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2676 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2677 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2678 Downstream Oxygen Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2679 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2680 Oxygen Sensor: Description and Operation CIRCUIT OPERATION Circuit A14 is a bus bar in the Power Distribution Center (PDC), and connects to battery voltage. The contact side of the Automatic Shut Down (ASD) relay connects circuit A14 and circuit A142. A 20 Amp fuse in the PDC protects circuits A14 and A142. Circuit A14 also supplies voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) controls the ground path circuit for the coil side of the ASD relay on circuit K51. Circuit K51 connects to cavity 67 of the PCM connector. Circuit A142 splices to supply voltage for the upstream and downstream heated oxygen sensors. The A142 circuit also splices to cavity 6 of the PCM. The input provided by circuit A142 at cavity 6 tells the PCM that the ASD relay energized. Circuit K41 delivers the signal from the upstream heated oxygen sensor to the PCM. Circuit K41 connects to cavity 30 of the PCM connector. Circuit K141 delivers the signal from the down-stream heated oxygen sensor to the PCM. Circuit K141 connects to cavity 51 of the PCM connector. The PCM provides a ground for the upstream and downstream heated oxygen sensor signals (circuit K41 and K141) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector Circuit Z1 provides ground for the heater circuits in each sensor. Circuit Z1 terminates at the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information Oxygen Sensor: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, ASD relay, generator, and the upstream and downstream heated oxygen sensors. The PCM controls the ground circuit for each of the components powered by circuit A142. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2683 Oxygen Sensor: Testing and Inspection Oxygen Sensor Heater Circuit Test NOTE: Use an ohmmeter to test the heating element of the oxygen sensors. 1. Disconnect the electrical connector from each oxygen sensor. - The white wires in the sensor connector are the power and ground circuits for the heater elements. 2. Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. - Replace the heated oxygen sensor if the resistance is not between 4 and 7 ohms. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor Oxygen Sensor: Service and Repair Downstream O2 Sensor Fig. 19 Downstream Heated Oxygen Sensor NOTE: The downstream heated oxygen sensor threads into the exhaust pipe behind the catalytic convertor (Fig. 19). REMOVAL 1. Raise vehicle. 2. Disconnect electrical connector from sensor. 3. Disconnect sensor electrical harness from clips along body. Fig. 20 Downstream Heated Oxygen Sensor Removal/Installation 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 20). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 2686 Oxygen Sensor: Service and Repair Upstream O2 Sensor Fig. 18 Upstream Heated Oxygen Sensor Removal/Installation REMOVAL 1. Raise and support vehicle. 2. Unplug sensor connector. 3. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 18). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 2687 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 2692 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2693 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2694 Power Steering Pressure Switch: Description and Operation Fig. 15 Power Steering Pressure Switch PURPOSE On vehicles equipped with power steering, a power steering pressure switch is used to improve the vehicle's idle quality. The pressure switch improves vehicle idle quality, by controlling engine idle speed when required. The switch (Fig. 15) provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. OPERATION The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed is increased. This increase in engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. When power steering pump pressure exceeds 2,758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. The power steering pressure switch is mounted directly to the power steering gear on vehicles requiring its usage. CIRCUIT OPERATION The power steering pressure switch opens and closes circuit K10 between the Powertrain Control Module (PCM) and ground. Circuit K10 connects to cavity 45 of the PCM connector. Circuit Z12 provides ground for the power steering pressure switch. The grounding point for circuit Z12 is the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2695 Power Steering Pressure Switch: Service and Repair CAUTION: When removing and installing the power steering pressure switch, the use of a 7/8 inch deep well socket is required. The deep well socket will prevent damage to the plastic, electrical connector area, of the power steering pressure switch. REMOVE 1. Disconnect negative battery cable from the negative post of the battery. Be sure cable is isolated from negative post on battery. 2. Raise vehicle. 3. Locate power steering pressure switch on back side of power steering gear. 4. Remove vehicle wiring harness connector, from power steering pressure switch. 5. Remove power steering pressure switch, from power steering gear. CAUTION: When tightening the power steering pressure switch after installation in steering gear, do not exceed the torque specification shown in step 1 below. Over-tightening may result in stripping the threads out of the pressure switch port on the steering gear. INSTALL 1. Install power steering pressure switch into power steering gear by hand until fully seated. Then torque power steering pressure switch to 8 Nm (70 inch lbs.). 2. Install vehicle wiring harness connector onto power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with locking tab on power steering pressure switch. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar (R), Power Steering Fluid, or equivalent. 3. Fill power steering reservoir to correct fluid level. 4. Connect negative cable back on negative post of battery. 5. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Specifications Powertrain Control Module: Specifications PCM 60-Way Connector Torque = 4 Nm (35 in lb) PCM Mounting Screws = 4 Nm (35 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Specifications > Page 2700 Fig. 100 Powertrain Control Module Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2703 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2704 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2705 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2706 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2707 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2708 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2709 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2710 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2711 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2712 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2713 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2714 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2715 Powertrain Control Module: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2716 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2717 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2718 Powertrain Control Module Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2719 Powertrain Control Module: Service Precautions - Before disconnecting any control module, make sure the ignition is off. Failure to do so could damage the module. - When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. - Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. - Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. - Operation of any type, including idling, should be avoided if engine misfiring occurs. Under this condition, the exhaust system operates at abnormally high temperature, which may cause damage to the catalyst or under-body parts of the vehicle. - Alteration or deterioration of ignition or fuel system, or any type of operating condition which results in engine misfiring must be corrected to avoid overheating the catalytic converter. - Proper maintenance and tune-up, according to manufacturer's specifications, should be made to correct abnormal conditions as soon as possible. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation Powertrain Control Module: Description and Operation Circuit Operation CIRCUIT OPERATION Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to cavity 46 of the Powertrain Control Module (PCM). A 20 Amp fuse in the PDC protects circuit A14. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 2722 Powertrain Control Module: Description and Operation PCM Operation Fig. 100 Powertrain Control Module Fig. 3 Data Link Connector The Powertrain Control Module (PCM) is a digital computer containing a microprocessor (Fig. 2). The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. PCM Inputs: Air Conditioning Controls - Battery Voltage - Battery Temperature Sensor - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Fuel Level Sensor - Ignition Switch (A21) - Intake Air Temperature Sensor - Knock Sensor - Manifold Absolute Pressure (MAP) Sensor - Oxygen Sensors - Power Steering Pressure Switch - SCI Receiver - Speed Control Switches - Throttle Position Sensor - Transmission Park/Neutral Switch (Automatic Transmission) - Vehicle Speed Sensor PCM Outputs: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 2723 - Air Conditioning Clutch Relay - Air Conditioning WOT Relay - Auto Shutdown (ASD) Relay - Charging Indicator Lamp - Data Link Connector - Duty Cycle EVAP Canister Purge Solenoid - EGR Solenoid - Fuel Injectors - Fuel Pump Relay - Generator Field - Idle Air Control Motor - Ignition Coils - Malfunction Indicator (Check Engine) Lamp - Radiator Fan Relay - Speed Control Solenoids - Tachometer - Torque Convertor Clutch Solenoid Based on inputs it receives, the PCM adjusts: Fuel Injector Pulse Width - Idle Speed - Ignition Spark Advance - Ignition Coil Dwell - EVAP Canister Purge Operation. The PCM Regulates: Cooling Fan - Air Conditioning - Speed Control System - Generator Charge Rate -- by Adjusting The Generator Field The PCM Also Performs Diagnostics The PCM adjusts injector pulse width (air-fuel ratio) based on: Battery Voltage - Coolant Temperature - Exhaust Gas Content (Oxygen Sensor) - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Manifold Absolute Pressure - Throttle Position The PCM adjusts ignition timing based on: Coolant Temperature - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Knock Sensor - Manifold Absolute Pressure - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) The PCM also adjusts engine idle speed through the idle air control motor based on: Air Conditioning Sense - Battery Temperature - Battery Voltage - Brake Switch - Coolant Temperature - Engine Speed (crankshaft Position Sensor) - Engine Run Time - Manifold Absolute Pressure - Power Steering Pressure Switch - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) - Vehicle Distance (Speed) ASD and Fuel Pump Relay Control Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 2724 The Auto Shutdown (ASD) and fuel pump relays are mounted externally, but turned on and off by the PCM. Crankshaft Position (Engine Speed) Signal The crankshaft position sensor signal is sent to the PCM. If the PCM does not receive the signal within approximately one second of engine cranking, it deactivates the ASD relay and fuel pump relay When these relays deactivate, power is shut off from the fuel injectors, ignition coils, heating element in the oxygen sensors and the fuel pump. PCM Regulated Output Supply Voltages The PCM contains a voltage converter that changes battery voltage to a regulated 8 volts direct current to power: Camshaft Position Sensor - Crankshaft Position Sensor - Vehicle Speed Sensor The PCM also provides a 5 volt direct current supply for: Manifold Absolute Pressure Sensor - Throttle Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 2725 Powertrain Control Module: Description and Operation System Operation SYSTEM OPERATION Powertrain Control Module The speed control electronic control circuitry is integrated into the Powertrain Control Module (PCM). The PCM is located in the engine compartment. The PCM speed control functions are monitored by the On-Board Diagnostics (OBD). All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. The PCM cannot be repaired and must be replaced if faulty. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview Circuit A14 connects to a bus bar in the PDC that the battery feeds. Circuit A14 powers the Automatic Shut Down (ASD) relay and fuel pump relay The A14 circuit also splices to the data link connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Page 2728 Powertrain Control Module: Service and Repair Fig. 100 Powertrain Control Module NOTE: The PCM attaches to the inner fender panel next to the washer fluid bottle on the driver side (Fig. 100). REMOVAL 1. Disconnect negative cable from battery 2. Disconnect positive cable from battery. 3. Remove washer bottle neck. 4. Squeeze tabs on Power Distribution Center (PDC) while pulling PDC up to remove it from bracket. - Lay PDC aside to gain access to PCM bracket screws. 5. Remove screws attaching PCM to body. 3. Lift PCM up and disconnect the 2 40-way connector 7. Remove PCM. INSTALLATION 1. Attach the 2 40-way connector to PCM. 2. Install PCM. Tighten mounting screws to 4 Nm (35 in lb) torque. 3. Install PDC by pushing down into brackets. 4. Install washer bottle neck. 5. Connect positive cable to battery. 6. Connect negative cable to battery. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig. 15 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2732 Power Distribution Center (Top) The relay is located in the Power Distribution Center (PDC). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector Auto Shutdown Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector > Page 2735 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Power Distribution Center (Bottom) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector > Page 2736 Power Distribution Center (Top) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2737 Automatic Shut Down (ASD) Relay: Description and Operation Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. CIRCUIT OPERATION The Automatic Shut Down (ASD) relay is located in the Power Distribution Center (PDC). Power for the coil and contact side of the relay is supplied on circuit A14. This circuit is HOT at all times and protected by a 20 Amp fuse located in the PDC. The Powertrain Control Module (PCM) controls the ground path for the coil side of the relay on circuit K51. This circuit connects to cavity 67 of the PCM. When the PCM supplies the ground path on circuit K51 the contacts in the relay CLOSE connecting circuits A14 and A142. The A142 circuit is spliced and supplies power to the generator, fuel injectors, PCM, ignition coil, and heated oxygen sensors. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 Amp fuse located in the PDC. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 2740 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 2741 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Service Precautions Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Service Precautions > Page 2746 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature. This temperature data, along with data from monitored line voltage, is used by the (PCM) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Battery Temperature Sensor The sensor is located forward of the vehicle battery, and is attached to the battery tray. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to Powertrain Management/Computer and Controls/Testing and Inspection. 1. The sensor is located under the battery and is attached to the battery tray. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25 °C (75-80 °F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) Ohms should be observed. 5. If reading is above or below the specification, replace the sensor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 2749 Battery Temperature Sensor: Service and Repair REMOVE 1. Make sure ignition switch is in OFF position and all accessories are OFF. Disconnect Battery Negative Cable 2. Remove battery negative cable first then the positive cable. Battery Thermoguard 3. Remove battery thermoguard. WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN. Air Inlet Tube Pull Strap Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 2750 4. Remove temperature sensor mounting nut from battery tray. Battery Temperature Sensor Connector 5. Disconnect sensor wire connector. INSTALL - For installation reverse above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis > Page 2755 Camshaft Position Sensor: Technical Service Bulletins Cam/Crank Sensor - No Start Diagnostics NO: 18-24-97 GROUP: Vehicle Performance DATE: Aug. 8, 1997 SUBJECT: No Start Diagnostics Cam/Crank Sensor $01 and $28 MODELS: 1997 (FJ) Avenger/Sebring/Talon 1997 (GS) Chrysler Voyager (International Market) 1997 (JA) Breeze/Cirrus/Stratus 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1997 (NS) Town & Country/Caravan/Voyager 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L DOHC/SOHC (NATURALLY ASPIRATED), 2.4L, 3.3L, 3.5L, OR 3.8L ENGINE. DISCUSSION: If a vehicle exhibits a no-start due to failure of the cam or crank sensor, the opposite sensor may be reported as the DTC (i.e. bad cam sensor sets crank sensor DTC and vice versa). The faulty sensor may generate a signal strong enough (at key "ON") to be interpreted by the controller as a legitimate signal. Since the engine is not running, the opposite sensor will not be generating any pulses. The controller, expecting corresponding pulses from both sensors, matures a fault for the sensor that is not generating any pulses. In this case, the good sensor is reported as faulty. To verify which sensor is at fault, use the DRB III and select DRB III Standalone, 1994 - 1998 Diagnostics, select Engine system, select Monitor Display, and No Start monitor. Under the No Start monitor the cam and crank sensors should display a no response or LOST on the display. If a sensor is reporting a signal at key ON", it should be replaced. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2758 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2759 Camshaft Position Sensor: Locations Camshaft Position Sensor Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2760 Camshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2761 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity OPERATION The camshaft position sensor attaches to the rear of the cylinder head. A target magnet attaches to the rear of the camshaft and indexes to the Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2762 correct position. The target magnet has four different poles arranged in an asymmetrical pattern (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the camshaft position sensor The K7 circuit connects to cavity 44 of the PCM connector. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 33 of the PCM connector. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing Camshaft Position Sensor: Testing and Inspection Component Testing The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting an oscilloscope and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing > Page 2765 Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing > Page 2766 Camshaft Position Sensor: Testing and Inspection Failure to Start Test Fig.20 Ignition Coil Engine Harness Connector This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Sensor Replacement Camshaft Position Sensor Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head. REMOVAL 1. Remove filtered air tube from the throttle body and air cleaner housing. 2. Disconnect electrical connector from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.35 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft (Fig. 35). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 2769 Fig.36 Target Magnet Installation NOTE: The target magnet has locating dowels that fit into machined locating holes in the end of the camshaft (Fig. 36). INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install filtered air tube. Tighten clamps to 3 Nm ±1 (25 in lb ±5) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 2770 Camshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 18 Nm (165 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2774 Engine Coolant Temperature Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2775 Engine Coolant Temperature Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2776 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig.13 Engine Coolant Temperature Sensor-DOHC PURPOSE The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. - The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. OPERATION As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The coolant sensor threads into the intake manifold next to the thermostat housing (Fig. 13). New sensors have sealant applied to the threads. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. The sensor also operates the engine cool and temperature gauge in the instrument cluster on circuit G20. See: Engine, Cooling and Exhaust/Cooling System/Lamps and Indicators Cooling System/Temperature Gauge/Description and Operation From circuit K2 the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes causing a change in current draw. The K2 circuit connects to cavity 26 of the PCM connector. The PCM provides ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig. 80 Engine Coolant Temperature Sensor Location-DOHC 1. With the key off, disconnect wire harness connector from coolant temperature sensor (Fig. 80). Fig. 27 Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 27). The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 28 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing > Page 2779 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Helpful Information The engine coolant temperature sensor is case grounded. The case ground provides the ground for the coolant temperature gauge circuit G20. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 2780 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig.39 Engine Coolant Temperature Sensor-DOHC NOTE: The engine coolant temperature sensor threads into the rear of the cylinder head. New sensors have sealant applied to the threads. REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. - Tighten to 18 Nm (165 in lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Cam/Crank Sensor - No Start Diagnostics Crankshaft Position Sensor: Technical Service Bulletins Cam/Crank Sensor - No Start Diagnostics NO: 18-24-97 GROUP: Vehicle Performance DATE: Aug. 8, 1997 SUBJECT: No Start Diagnostics Cam/Crank Sensor $01 and $28 MODELS: 1997 (FJ) Avenger/Sebring/Talon 1997 (GS) Chrysler Voyager (International Market) 1997 (JA) Breeze/Cirrus/Stratus 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1997 (NS) Town & Country/Caravan/Voyager 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L DOHC/SOHC (NATURALLY ASPIRATED), 2.4L, 3.3L, 3.5L, OR 3.8L ENGINE. DISCUSSION: If a vehicle exhibits a no-start due to failure of the cam or crank sensor, the opposite sensor may be reported as the DTC (i.e. bad cam sensor sets crank sensor DTC and vice versa). The faulty sensor may generate a signal strong enough (at key "ON") to be interpreted by the controller as a legitimate signal. Since the engine is not running, the opposite sensor will not be generating any pulses. The controller, expecting corresponding pulses from both sensors, matures a fault for the sensor that is not generating any pulses. In this case, the good sensor is reported as faulty. To verify which sensor is at fault, use the DRB III and select DRB III Standalone, 1994 - 1998 Diagnostics, select Engine system, select Monitor Display, and No Start monitor. Under the No Start monitor the cam and crank sensors should display a no response or LOST on the display. If a sensor is reporting a signal at key ON", it should be replaced. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2787 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position Sensor Bolts ........................................................................................................ .......................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2788 Fig 7 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2789 Crankshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2790 Crankshaft Position Sensor: Description and Operation Fig 7 Crankshaft Position Sensor Fig. 14 Timing Reference Notches Fig.6 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60° signature notch (Fig. 14). The notches generate pulses from high to low in the crankshaft position sensor output voltage. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2791 - When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69° before top dead center (BTDC). - The second notch represents 49° BTDC. - The third notch represents 29°. - The last notch in each set represents 9° before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM connector. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test Fig.20 Ignition Coil Engine Harness Connector This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 2794 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig 7 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Crankshaft Position Sensor Bolts torque ....................................................................................................................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2797 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > General Description Fuel Level Sensor: Description and Operation General Description Fig. 10 Level Sensor Diagnosis OPERATION The fuel gauge sending unit is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and two variable resistors (tracks). These two tracks are used to send two different electrical signals. One is used for fuel gauge operation and the other is for OBD II emission requirements. Track 1 fuel gauge operation: As the fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge on the instrument panel to read full. As the fuel level decreases, the float and arm move down. This increases the sending unit resistance, causing the fuel gauge on the instrument panel to read empty Track 2-OBD II emission requirements: A variable voltage signal is sent to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes if the fuel level in the tank is less than 15 percent of its rated capacity. CIRCUIT OPERATION Circuit G4 provides an input to the Powertrain Control Module (PCM) indicating fuel tank level. This circuit connects to cavity 23 of the PCM connector. The G4 circuit is also used for the fuel gauge located in the instrument cluster. For operation of fuel gauge, See: Instrument Panel, Gauges and Warning Indicators/Fuel Gauge/Description and Operation Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > General Description > Page 2802 Fuel Level Sensor: Description and Operation Related Trouble Codes and Set Conditions Fuel Level Sending Unit Volts Too High Name of Code: Fuel Level Sending Unit Volts Too High When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes above a calculated value. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel systems monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Open sensor signal circuit - Fuel level sending unit failure - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Fuel Level Sending Unit Volts Too Low Name of Code: Fuel Level Sending Unit Volts Too Low When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes below 0.10 volts. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel system monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Sensor signal circuit shorted to ground - Fuel level sending unit failure - Loss of fuel ignition switch output voltage - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Sending Unit Operation Check Fuel Level Sensor: Testing and Inspection Sending Unit Operation Check When a problem occurs with a cluster gauge check for a defective sending unit or wiring. Do this before disassembling the cluster. 1. Sending units and wiring can be checked by grounding the connector leads at the sending unit in the vehicle. 2. With the ignition in the ON position, a grounded input will cause the fuel or temperature gauge to read at or above maximum. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 2805 Fuel Level Sensor: Testing and Inspection Sending Unit Voltage Check Fig. 1 Fuel Guage Test Terminal 1. Remove the fuel gauge electrical harness. 2. Connect 12 volt test light to the fuel gauge and ground terminal. 3. Turn ignition to On position and proceed as follows: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 2806 a. If test light illuminates and pointer of gauge does not swing, replace fuel gauge. b. If test light illuminates and pointer of gauge swings, replace fuel gauge unit. c. If test light does not light and pointer of gauge does not swing, check the electrical harness for kinks chaffing and broken wires. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 2807 Fuel Level Sensor: Testing and Inspection Sending Unit Resistance Check Fig. 10 Level Sensor Diagnosis This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. To test the level sensor, connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector. Move the float lever to the positions shown in the resistance chart. Record the resistance at each point. Replace the level sensor if the resistance is not within specifications. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Page 2808 Fuel Level Sensor: Service and Repair Fig. 21 Fuel Pump/Level Sensor Electrical Connector NOTE: Remove fuel pump module prior to beginning this procedure. REMOVAL 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector. Fig. 22 Wire Terminal Locking Wedge 2. Pull off blue locking wedge. Fig. 23 Wire Terminal Locking Finger 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection > Page 2809 Fig. 24 Removing Wires From Connector 4. Push level sensor signal and ground terminals out of the connector. Fig. 25 Loosening Level Sensor 5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Fig. 26 Level Sensor Removal/Installation 6. Push level sensor down slightly. - Ensure tab at bottom of sensor locks in place. 7. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 8. Install locking wedge on connector. 9. Push connector up into bottom of fuel pump module electrical connector. 10. Install fuel pump module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications MAP Sensor Torque Aluminum Manifold = 3 Nm (30 in lbs) Plastic Manifold = 2 Nm (20 in lbs) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2813 Map/Intake Air Temperature Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2814 Intake Air Temperature Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2815 Intake Air Temperature Sensor: Description and Operation Fig.15 MAP/IAT Sensor-DOHC PURPOSE The intake air temperature sensor measures the temperature of the air as it enters the engine. The sensor supplies one of the inputs the PCM uses to determine injector pulse-width. CONSTRUCTION The MAP/Intake Air Temperature (IAT) sensor, located on the intake manifold, combines the MAP and Intake Air Temperature (IAT) functions into one sensor. CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. Circuit K21 connects to cavity 37 of the PCM connector. From circuit K21 the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor As intake air temperature changes the resistance in the sensor changes causing a change in current draw. The PCM provides ground for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Intake Air Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 2818 Intake Air Temperature Sensor: Service and Repair Map/Intake Air Temperature Sensor Fig. 98 MAP/IAT Sensor-DOHC NOTE: The MAP/IAT sensor attaches to the intake manifold plenum (Fig. 98). Fig. 97 Air Inlet Duct-DOHC REMOVAL 1. Remove air inlet duct wing nut and duct from intake manifold (Fig. 97). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 2819 2. Disconnect the electrical connector from the MAP/IAT sensor. 3. Remove sensor mounting screws. 4. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seals. 2. Tighten mounting screws to 2 Nm (20 in lb) torque for a plastic manifold and 3 Nm (30 in lb) for a aluminum manifold. 3. Attach electrical connector to sensor 4. Install air inlet duct wing nut and duct from intake manifold, insure that the duct does not interfer with ignition cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2823 Knock Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2824 Knock Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2825 Knock Sensor: Description and Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 24 of the PCM connector. The PCM provides ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Helpful Information Knock Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2828 Knock Sensor: Testing and Inspection Component Testing The knock sensor can be tested with a digital voltmeter. Sensor output should be between 80 mV and 4 volts with the engine running between 576 and 2,208 rpm. If the output falls outside of this range a DTC will be set. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Page 2829 Knock Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications Manifold Pressure/Vacuum Sensor: Electrical Specifications The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications > Page 2834 Manifold Pressure/Vacuum Sensor: Mechanical Specifications MAP Sensor Torque Aluminum Manifold = 3 Nm (30 in lbs) Plastic Manifold = 2 Nm (20 in lbs) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2835 Map Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2836 IAT/Map Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2837 Manifold Pressure/Vacuum Sensor: Description and Operation Fig.15 MAP/IAT Sensor-DOHC OPERATION The PCM supplies 5 volts to the MAP sen son The MAP sensor function converts intake manifold pressure into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP sensor voltage decreases proportionately. Also, as vacuum decreases, MAP sensor voltage increases proportionately. During cranking, before the engine starts running, the PCM determines atmosphenc air pressure from the MAP sensor voltage. While the engine operates, the PCM determines intake manifold pressure from the MAP sensor voltage. Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and the air/fuel mixture. The MAP/Intake Air Temperature Sensor (MAP/IAT) sensor mounts to the intake manifold. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Manifold Absolute Pressure (MAP) sensor. Circuit K6 connects to cavity 61 of the PCM connector. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity 36 of the PCM connector. The PCM provides ground for the MAP sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing Manifold Pressure/Vacuum Sensor: Testing and Inspection Component Testing Fig. 82 MAP Sensor Connector CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 1 and 4 (Fig. 82). With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. If OK, go to next step. - If not OK, go to step 3. 2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness condition. Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 43. - If OK, go to next step. - If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 3 and 1 with the key ON. The voltage should be approximately 5 volts ± 0.5V). Five volts (± 0.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor. - If not OK, repair or replace the wire harness as required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing > Page 2840 Manifold Pressure/Vacuum Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 2841 Manifold Pressure/Vacuum Sensor: Service and Repair Map/Intake Air Temperature Sensor Fig. 98 MAP/IAT Sensor-DOHC NOTE: The MAP/IAT sensor attaches to the intake manifold plenum (Fig. 98). Fig. 97 Air Inlet Duct-DOHC REMOVAL 1. Remove air inlet duct wing nut and duct from intake manifold (Fig. 97). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 2842 2. Disconnect the electrical connector from the MAP/IAT sensor. 3. Remove sensor mounting screws. 4. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seals. 2. Tighten mounting screws to 2 Nm (20 in lb) torque for a plastic manifold and 3 Nm (30 in lb) for a aluminum manifold. 3. Attach electrical connector to sensor 4. Install air inlet duct wing nut and duct from intake manifold, insure that the duct does not interfer with ignition cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Upstream and Downstream Heated Oxygen Sensors Torque = 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2848 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2849 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2850 Downstream Oxygen Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2851 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2852 Oxygen Sensor: Description and Operation CIRCUIT OPERATION Circuit A14 is a bus bar in the Power Distribution Center (PDC), and connects to battery voltage. The contact side of the Automatic Shut Down (ASD) relay connects circuit A14 and circuit A142. A 20 Amp fuse in the PDC protects circuits A14 and A142. Circuit A14 also supplies voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) controls the ground path circuit for the coil side of the ASD relay on circuit K51. Circuit K51 connects to cavity 67 of the PCM connector. Circuit A142 splices to supply voltage for the upstream and downstream heated oxygen sensors. The A142 circuit also splices to cavity 6 of the PCM. The input provided by circuit A142 at cavity 6 tells the PCM that the ASD relay energized. Circuit K41 delivers the signal from the upstream heated oxygen sensor to the PCM. Circuit K41 connects to cavity 30 of the PCM connector. Circuit K141 delivers the signal from the down-stream heated oxygen sensor to the PCM. Circuit K141 connects to cavity 51 of the PCM connector. The PCM provides a ground for the upstream and downstream heated oxygen sensor signals (circuit K41 and K141) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector Circuit Z1 provides ground for the heater circuits in each sensor. Circuit Z1 terminates at the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information Oxygen Sensor: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, ASD relay, generator, and the upstream and downstream heated oxygen sensors. The PCM controls the ground circuit for each of the components powered by circuit A142. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2855 Oxygen Sensor: Testing and Inspection Oxygen Sensor Heater Circuit Test NOTE: Use an ohmmeter to test the heating element of the oxygen sensors. 1. Disconnect the electrical connector from each oxygen sensor. - The white wires in the sensor connector are the power and ground circuits for the heater elements. 2. Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. - Replace the heated oxygen sensor if the resistance is not between 4 and 7 ohms. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor Oxygen Sensor: Service and Repair Downstream O2 Sensor Fig. 19 Downstream Heated Oxygen Sensor NOTE: The downstream heated oxygen sensor threads into the exhaust pipe behind the catalytic convertor (Fig. 19). REMOVAL 1. Raise vehicle. 2. Disconnect electrical connector from sensor. 3. Disconnect sensor electrical harness from clips along body. Fig. 20 Downstream Heated Oxygen Sensor Removal/Installation 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 20). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 2858 Oxygen Sensor: Service and Repair Upstream O2 Sensor Fig. 18 Upstream Heated Oxygen Sensor Removal/Installation REMOVAL 1. Raise and support vehicle. 2. Unplug sensor connector. 3. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 18). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 2859 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 2864 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2865 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2866 Power Steering Pressure Switch: Description and Operation Fig. 15 Power Steering Pressure Switch PURPOSE On vehicles equipped with power steering, a power steering pressure switch is used to improve the vehicle's idle quality. The pressure switch improves vehicle idle quality, by controlling engine idle speed when required. The switch (Fig. 15) provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. OPERATION The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed is increased. This increase in engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. When power steering pump pressure exceeds 2,758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. The power steering pressure switch is mounted directly to the power steering gear on vehicles requiring its usage. CIRCUIT OPERATION The power steering pressure switch opens and closes circuit K10 between the Powertrain Control Module (PCM) and ground. Circuit K10 connects to cavity 45 of the PCM connector. Circuit Z12 provides ground for the power steering pressure switch. The grounding point for circuit Z12 is the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2867 Power Steering Pressure Switch: Service and Repair CAUTION: When removing and installing the power steering pressure switch, the use of a 7/8 inch deep well socket is required. The deep well socket will prevent damage to the plastic, electrical connector area, of the power steering pressure switch. REMOVE 1. Disconnect negative battery cable from the negative post of the battery. Be sure cable is isolated from negative post on battery. 2. Raise vehicle. 3. Locate power steering pressure switch on back side of power steering gear. 4. Remove vehicle wiring harness connector, from power steering pressure switch. 5. Remove power steering pressure switch, from power steering gear. CAUTION: When tightening the power steering pressure switch after installation in steering gear, do not exceed the torque specification shown in step 1 below. Over-tightening may result in stripping the threads out of the pressure switch port on the steering gear. INSTALL 1. Install power steering pressure switch into power steering gear by hand until fully seated. Then torque power steering pressure switch to 8 Nm (70 inch lbs.). 2. Install vehicle wiring harness connector onto power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with locking tab on power steering pressure switch. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar (R), Power Steering Fluid, or equivalent. 3. Fill power steering reservoir to correct fluid level. 4. Connect negative cable back on negative post of battery. 5. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2872 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2873 Throttle Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2874 Throttle Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2875 Throttle Position Sensor: Description and Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS mounts to the throttle body and connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- from 0.38 to 1.03 volts. - AT Wide open throttle -- 3.1 to 4.0 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). CIRCUIT OPERATION From the Powertrain Control Module (PCM) circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2878 Throttle Position Sensor: Testing and Inspection Component Testing To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool and follow the appropriate procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for correct pinout. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2879 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2880 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (20 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Throttle Position Sensor Mounting Screws 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2884 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2885 Transmission Position Switch/Sensor: Description and Operation Fig. 20 Park/Neutral Switch OPERATION On vehicles with 3-speed automatic transmission the park/neutral switch provides an input to the Powertrain Control Module (PCM). The park/neutral position switch is located on the automatic transaxle housing Fig. 20. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. CIRCUIT OPERATION When CLOSED the Transmission Range Switch (TRS) provides an input to the Powertrain Control Module (PCM) on circuit T41. This circuit connects to cavity 76 of the PCM connector. The T41 circuit is spliced and provides a ground path for the engine starter relay, and the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Mounting Bolt 2.2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 2889 Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2892 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2893 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2894 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2895 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2896 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2897 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2898 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2899 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2900 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2901 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2902 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2903 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2904 Vehicle Speed Sensor: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2905 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2906 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2907 Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > System Operation Vehicle Speed Sensor: Description and Operation System Operation SYSTEM OPERATION The Vehicle Speed Sensor (VSS) is a pulse generator mounted to an adapter near the transmission output shaft. The sensor is driven through the adapter by a speedometer pinion gear. The VSS pulse signal to the speedometer/odometer is monitored by the PCM speed control circuitry to determine vehicle speed and to maintain speed control set speed. Refer to the Powertrain Management/Computer and Control Systems/Diagnostic Procedures for diagnosis and testing of this component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > System Operation > Page 2910 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor-PCM Input Fig. 17 Vehicle Speed Sensor -- Automatic Transmission Fig. 18 Vehicle Speed Sensor -- Manual Transmission PURPOSE The sensor input is used by the PCM to determine vehicle speed and distance traveled. OPERATION The vehicle speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a closed throttle signal from the throttle position sensor, indicate a closed throttle deceleration to the PCM. Under deceleration conditions, the PCM adjusts the Idle Air Control (IAC) motor to maintain a desired MAP value. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. The vehicle speed sensor signal is also used to operate: Speedometer - Speed control - Daytime Running Lights (Canadian Vehicles only). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the Vehicle Speed Sensor (VSS). The K7 circuit connects to cavity 44 of the PCM connector. Circuit G7 from the VSS provides an input signal to the PCM. The G7 circuit connects to cavity 66 of the PCM connector. The PCM provides ground for the VSS signal (circuit G7) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Helpful Information Vehicle Speed Sensor: Testing and Inspection Helpful Information Circuit G7 splices to the speedometer and odometer in the instrument cluster. Circuit K7 splices to supply 8 Volts to the camshaft position sensor and crankshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 2913 Vehicle Speed Sensor: Service and Repair Fig. 24 Vehicle Speed Sensor Fig. 7 Vehicle Speed Sensor And Connector Fig. 8 Vehicle Speed Sensor And Speedometer Pinion Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 2914 NOTE: The vehicle speed sensor is located in the transmission extension housing (Fig. 24). REMOVAL 1. Disconnect electrical connector from sensor. 2. Remove the sensor mounting bolt. 3. Lift the sensor out of the transaxle extension housing. Ensure the 0-ring was removed with the sensor. NOTE: The speed sensor gear meshes with a gear on the output shaft. INSTALLATION 1. With 0-ring in place, install sensor and seat sensor by hand -- to ensure proper gear engagement. 2. Install mounting bolt and torque bolt to 2.2 Nm (20 in lb). 3. Connect electrical connector to sensor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2919 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2920 Throttle Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2921 Throttle Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2922 Throttle Position Sensor: Description and Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS mounts to the throttle body and connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- from 0.38 to 1.03 volts. - AT Wide open throttle -- 3.1 to 4.0 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). CIRCUIT OPERATION From the Powertrain Control Module (PCM) circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2925 Throttle Position Sensor: Testing and Inspection Component Testing To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool and follow the appropriate procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for correct pinout. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2926 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2927 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (20 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Torque Reduction Signal > Component Information > Description and Operation Torque Reduction Signal: Description and Operation TORQUE MANAGEMENT INPUT Circuit T10 connects from the Transmission Control Module (TCM) to the Powertrain Control Module (PCM) cavity 63. This is the torque management request from the TCM to the PCM. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Throttle Position Sensor Mounting Screws 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2935 Transmission Position Switch/Sensor: Description and Operation Fig. 20 Park/Neutral Switch OPERATION On vehicles with 3-speed automatic transmission the park/neutral switch provides an input to the Powertrain Control Module (PCM). The park/neutral position switch is located on the automatic transaxle housing Fig. 20. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. CIRCUIT OPERATION When CLOSED the Transmission Range Switch (TRS) provides an input to the Powertrain Control Module (PCM) on circuit T41. This circuit connects to cavity 76 of the PCM connector. The T41 circuit is spliced and provides a ground path for the engine starter relay, and the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Mounting Bolt 2.2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 2939 Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2942 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2943 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2944 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2945 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2946 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2947 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2948 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2949 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2950 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2951 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2952 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2953 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2954 Vehicle Speed Sensor: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2955 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2956 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2957 Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > System Operation Vehicle Speed Sensor: Description and Operation System Operation SYSTEM OPERATION The Vehicle Speed Sensor (VSS) is a pulse generator mounted to an adapter near the transmission output shaft. The sensor is driven through the adapter by a speedometer pinion gear. The VSS pulse signal to the speedometer/odometer is monitored by the PCM speed control circuitry to determine vehicle speed and to maintain speed control set speed. Refer to the Powertrain Management/Computer and Control Systems/Diagnostic Procedures for diagnosis and testing of this component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > System Operation > Page 2960 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor-PCM Input Fig. 17 Vehicle Speed Sensor -- Automatic Transmission Fig. 18 Vehicle Speed Sensor -- Manual Transmission PURPOSE The sensor input is used by the PCM to determine vehicle speed and distance traveled. OPERATION The vehicle speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a closed throttle signal from the throttle position sensor, indicate a closed throttle deceleration to the PCM. Under deceleration conditions, the PCM adjusts the Idle Air Control (IAC) motor to maintain a desired MAP value. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. The vehicle speed sensor signal is also used to operate: Speedometer - Speed control - Daytime Running Lights (Canadian Vehicles only). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the Vehicle Speed Sensor (VSS). The K7 circuit connects to cavity 44 of the PCM connector. Circuit G7 from the VSS provides an input signal to the PCM. The G7 circuit connects to cavity 66 of the PCM connector. The PCM provides ground for the VSS signal (circuit G7) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Helpful Information Vehicle Speed Sensor: Testing and Inspection Helpful Information Circuit G7 splices to the speedometer and odometer in the instrument cluster. Circuit K7 splices to supply 8 Volts to the camshaft position sensor and crankshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 2963 Vehicle Speed Sensor: Service and Repair Fig. 24 Vehicle Speed Sensor Fig. 7 Vehicle Speed Sensor And Connector Fig. 8 Vehicle Speed Sensor And Speedometer Pinion Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 2964 NOTE: The vehicle speed sensor is located in the transmission extension housing (Fig. 24). REMOVAL 1. Disconnect electrical connector from sensor. 2. Remove the sensor mounting bolt. 3. Lift the sensor out of the transaxle extension housing. Ensure the 0-ring was removed with the sensor. NOTE: The speed sensor gear meshes with a gear on the output shaft. INSTALLATION 1. With 0-ring in place, install sensor and seat sensor by hand -- to ensure proper gear engagement. 2. Install mounting bolt and torque bolt to 2.2 Nm (20 in lb). 3. Connect electrical connector to sensor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Specifications Voltage Signal: Specifications The PCM tries to maintain system voltage between 12.9 volts and 15.0 volts. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Specifications > Page 2968 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Specifications > Page 2969 Voltage Signal: Description and Operation THEORY OF OPERATION: The PCM monitors battery voltage input to determine fuel injector pulse width and generator field control voltage. Injector Pulse Width If voltage is low the PCM will increase pulse width (the period of time that the injector is energized). Generator Field Voltage The PCM tries to maintain a system voltage between 12.9 volts and 15.0 volts. The voltage determined by the PCM as the final goal for the charging system is called "control" voltage. This control voltage is determined from the battery temp sensor for ambient sensor and the sensed voltage system voltage at the PCM. The control voltage is compared to the sensed voltage continuously during running. If the sensed voltage is less than the control voltage the PCM will supply more ground to the field circuit. - If the sensed voltage is more than the control voltage the PCM will supply less ground to the field circuit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Description and Operation Catalyst Shield: Description and Operation CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts. PURPOSE The heat shield is needed to protect both the car and the environment from the high temperatures developed in the vicinity of the catalytic converter. CAUTION: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shield on cars. Light over-spray near the edges is permitted. Application of coating will greatly reduce the efficiency of the heat shields resulting in excessive floor pan temperatures and objectionable fumes. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications Canister Purge Solenoid: Specifications Solenoid Coil Resistance @ 20°C (68°F) ......................................................................................................................................................... 25 - 35 ohms Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 2979 Canister Purge Solenoid: Locations Fig. 101 Upstream Heated Oxygen Sensor Removal/Installation & EVAP Purge Solenoid Location EVAP Purge Solenoid Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 2980 Evaporative Solenoid Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 2981 Canister Purge Solenoid: Description and Operation Fig. 101 Upstream Heated Oxygen Sensor Removal/Installation & EVAP Purge Solenoid Location PURPOSE The duty cycle EVAP purge solenoid regulates the rate of vapor flow from the EVAP canister to the throttle body. The PCM operates the solenoid. OPERATION During the cold start warm-up period and the hot start time delay, the PCM does not energize the solenoid. When de-energized, no vapors are purged. When purging, the PCM energizes and de-energizes the solenoid approximately 5 or 10 times per second, depending upon operating conditions. The PCM varies the vapor flow rate by changing solenoid pulse width. - Pulse width is the amount of time the solenoid energizes. The solenoid attaches to a bracket which is attached to the front engine mount (Fig. 101). CIRCUIT OPERATION Circuit F12 supplies battery voltage to the Duty Cycle EVAP/Purge solenoid. The Powertrain Control Module (PCM) switches ground path for the solenoid ON and OFF through circuit K52. Circuit F12 connects to a bus bar in the fuse block fed by circuit A21. A 15 Amp fuse in the fuse block, cavity 10, protects circuit F12. Circuit F12 also connects to cavity 20 of the PCM connector. Circuit K52 connects to cavity 68 of the PCM, and cavity 1 of the solenoid connector. NOTE: The solenoid will not operate properly unless it is installed with the electrical connector at the top. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Testing and Inspection > EVAP Purge Solenoid Inspection Canister Purge Solenoid: Testing and Inspection EVAP Purge Solenoid Inspection EVAPORATIVE EMISSION PURGE SOLENOID INSPECTION NOTE: When disconnecting the vacuum hose, place an identification mark on it for proper re-connection. 1. Disconnect the vacuum hose from the solenoid valve. 2. Disconnect the harness connector. 3. Connect a hand vacuum pump to nipple (A) of the solenoid valve. 4. Check airtightness by applying a vacuum with voltage applied directly from the battery to the purge control solenoid valve. Battery Voltage / Normal Condition. Applied ....................................................................................... .......................................................................................................... Vacuum Leaks Not Applied ...... .............................................................................................................................................................. ............. Vacuum Maintained 5. Measure the resistance between the terminals of the solenoid valve. - Standard value: 25-35 ohms [at 20°C (68°F)] Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Testing and Inspection > EVAP Purge Solenoid Inspection > Page 2984 Canister Purge Solenoid: Testing and Inspection Helpful Information Circuit F12 splices to feed the Antilock Brake System (ABS) control module, PCM, Electronic EGR Transducer (EET) solenoid, leak detection pump, and the Torque Converter Clutch (TCC) solenoid. The F12 circuit also connects to a bus bar in the Power Distribution Center (PDC) that supplies voltage to the coil side of radiator fan relays, A/C clutch relay, and fuel pump relay. In the START or RUN position, the ignition switch connects circuit A1 from the fuse block and circuit A21. Circuit A1 connects to battery voltage and is protected by a 30 Amp fuse in the PDC. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Testing and Inspection > Page 2985 Canister Purge Solenoid: Service and Repair Fig. 101 Upstream Heated Oxygen Sensor Removal/Installation & EVAP Purge Solenoid Location NOTE: The solenoid attaches to a bracket near the front engine mount. The solenoid will not operate unless it is installed correctly REMOVAL 1. Disconnect electrical connector from solenoid. 2. Disconnect vacuum tubes from solenoid. 3. Remove solenoid from bracket. NOTE: The top of the solenoid has TOP printed on it. The solenoid will not operate unless it is installed correctly. INSTALLATION 1. Install solenoid on bracket. 2. Connect vacuum tube to solenoid. 3. Connect electrical connector to solenoid. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Fig.1 EVAP Canister Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2989 Evaporative Emission Control Canister: Description and Operation Fig. 2 EVAP Canister All vehicles use a sealed, maintenance free, evaporative (EVAP) canister. Fuel tank pressure vents into the canister. The canister temporarily holds the fuel vapors until intake manifold vacuum draws them into the combustion chamber. The PCM purges the canister through the duty cycle EVAP purge solenoid. - The PCM purges the canister at predetermined intervals and engine conditions. The canister mounts to a bracket behind the front fascia on the passengers side of the vehicle (Fig. 2). The vacuum and vapor tube connect to the top of the canister. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > EVAP System - Leak Detection Pump Misdiagnosis Leak Detection Pump: Technical Service Bulletins EVAP System - Leak Detection Pump Misdiagnosis NUMBER: 18-01-00 GROUP: Vehicle Performance DATE: Feb. 4, 2000 SUBJECT: Misdiagnosed Leak Detection Pump Systems With DTC P1494, P0442, P0455, OR P0456 MODELS: 1997 - 2000 (AB) Ram Van 1997 - 2000 (AN) Dakota 1997 - 2000 (BR/BE) Ram truck 1998 - 2000 (DN) Durango 1997 - 2000 (FJ) Avenger/Sebring/Talon 1997 - 2000 (JA) Cirrus/Stratus/Breeze 1997 - 2000 (JX) Sebring Convertible 1997 - 2000 (LH) Concorde/Intrepid/LHS/3OOMNision 1997 - 2000 (NS) Town & Country/CaravanNoyager 1997 2000 (PL) Neon 1997 - 2000 (PR) Prowler 1997 - 2000 (SR) ViperNiper GIS 1997 - 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1997 - 2000 (XJ) Cherokee 1997 - 1998 (ZJ) GrandCherokee DISCUSSION: During evaporative system diagnosis, Leak Detection Pumps have mistakenly been replaced. A thorough inspection for pinched, kinked, or disconnected supply vacuum lines (as currently listed in the Powertrain Diagnostic Procedures) is a critical step in diagnosing DTC P1494 (LDP SW OR MECHANICAL FAULT). Additionally, the other evaporative leak faults (DTC P0442 SMALL LEAK, P0455 - LARGE LEAK, and P0456 - VERY SMALL LEAK) should have the supply vacuum lines examined for pinches or kinks prior to any LDP component replacement. The supply vacuum lines should be checked from the engine compartment all the way to the fuel tank, including the LDP and purge system. NOTE: VERIFY ALL RELATED SUPPLY VACUUM LINE ROUTINGS FOR PINCHES, KINKS, OR DISCONNECTION'S BEFORE REPLACING LDP SYSTEM COMPONENTS. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Vacuum Pump Leak Detection Pump Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Vacuum Pump > Page 2996 EVAP System Service Port Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 2997 Leak Detection Pump Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 2998 Leak Detection Pump: Description and Operation Fig 4 Evaporative System Monitor PURPOSE The leak detection pump is a device used to detect a leak in the evaporative system. OPERATION The pump contains a 3 port solenoid, a pump that contains a switch, a spring loaded canister vent valve seal, 2 check valves and a spring diaphragm. Immediately after a cold start, engine temperature between 40°F and 86°F, the 3 port solenoid is briefly energized. This initializes the pump by drawing air into the pump cavity and also closes the vent seal. During non-test test conditions, the vent seal is held open by the pump diaphragm assembly which pushes it open at the fill travel position. The vent seal will remain closed while the pump is cycling. This is due to the operation of the 3 port solenoid which prevents the diaphragm assembly from reaching full travel. After the brief initialization period, the solenoid is de-energized, allowing atmospheric pressure to enter the pump cavity. This permits the spring to drive the diaphragm which forces air out of the pump cavity and into the vent system. When the solenoid is energized and de-energized, the cycle is repeated creating flow in typical diaphragm pump fashion. The pump is controlled in 2 modes: PUMP MODE: The pump is cycled at a fixed rate to achieve a rapid pressure build in order to shorten the overall test time. TEST MODE: The solenoid is energized with a fixed duration pulse. Subsequent fixed pulses occur when the diaphragm reaches the switch closure point. Leak Test The spring in the pump is set so that the system will achieve an equalized pressure of about 7.5 inches of water. When the pump starts, the cycle rate is quite high. As the system becomes pressurized pump rate drops. If there is no leak the pump will quit. - If there is a leak, the test is terminated at the end of the test mode. Purge Monitor If there is no leak, the purge monitor is run. If the cycle rate increases due to the flow through the purge system, the test is passed and the diagnostic is complete. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 2999 The canister vent valve will unseal the system after completion of the test sequence as the pump diaphragm assembly moves to the full travel position. CIRCUIT OPERATION Power for the vapor canister leak detector is provided on circuit F12. This circuit is protected by a 15 Amp fuse located in cavity 10 of the fuse block. Power for the fuse is supplied on circuit A21 from the ignition switch. Circuit A21 is HOT in the START and RUN position only. The Powertrain Control Module (PCM) controls the ground path for the leak detection pump solenoid and leak detection pump switch. Circuit K106 is connected to cavity 77 of the PCM connector and to the leak detection solenoid. Circuit K107 is connected to cavity 72 of the PCM connector and to the leak detection pump switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Description and Operation EGR Backpressure Transducer: Description and Operation Fig. 1 EGR System Fig. 2 Electronic EGR Transducer (EET) The electronic EGR transducer (EET) contains an electrically operated solenoid and a back-pressure transducer (Fig. 2). The Powertrain Control Module (PCM) operates the solenoid. Exhaust system back-pressure controls the transducer. When exhaust system back-pressure becomes high enough, it fully closes a bleed valve in the transducer. - When the PCM de-energizes the solenoid and back-pressure closes the transducer bleed valve, vacuum flows through the transducer to operate the EGR valve. De-energizing the solenoid, but not fully closing the transducer bleed hole (because of low back-pressure), varies the strength of vacuum applied to the EGR valve. Varying the strength of the vacuum changes the amount of EGR supplied to the engine. This provides the correct amount of exhaust gas recirculation for different operating conditions. This system does not allow EGR at idle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Description and Operation > Page 3004 EGR Backpressure Transducer: Service and Repair Fig. 1 EGR System NOTE: If the EGR system operates incorrectly, replace the entire EGR valve and transducer together. The EGR valve and Electronic EGR Transducer (EET) are calibrated together. NOTE: The EGR valve and EET attach to the rear of the cylinder head (Fig. 1). REMOVAL 1. Disconnect vacuum supply tube from EET solenoid. 2. Disconnect electrical connector from solenoid. 3. Remove EGR tube to EGR valve screws. 4. Remove EGR valve mounting screws. Remove EGR valve and transducer. 5. Clean gasket surfaces. Discard old gaskets. If necessary, clean EGR passages. INSTALLATION 1. Loosely install EGR valve with new gaskets. 2. Finger tighten EGR tube fasteners. 3. Tighten EGR tube fasteners to 11 Nm (95 in lb) torque. 4. Tightening EGR valve mounting screws to 22 Nm (200 in lb) torque. 5. Connect vacuum supply tube to solenoid. 6. Attach electrical connector to solenoid. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations EGR System Components Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 3008 EGR Solenoid Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 3009 EGR Control Solenoid: Description and Operation CIRCUIT OPERATION Circuit F12 supplies battery voltage to the Electronic EGR Transducer (EET) solenoid. The Powertrain Control Module (PCM) switches ground path for the solenoid ON and OFF through circuit K35. Circuit F12 connects to a bus bar in the fuse block fed by circuit A21. A 15 Amp fuse in the fuse block, cavity 10, protects circuit F12. Circuit F12 also connects to cavity 20 of the PCM. Circuit K35 connects to cavity 40 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview EGR Control Solenoid: Initial Inspection and Diagnostic Overview Circuit F12 splices to feed the ABS control module, PCM, Duty Cycle EVAP/Purge solenoid, leak detection pump, and the TCC solenoid. The F12 circuit also connects to a bus bar in the Power Distribution Center (PDC) that supplies voltage to the coil side of radiator fan relays, A/C clutch relay, and fuel pump relay. In the START or RUN position, the ignition switch connects circuit A1 from the fuse block and circuit A21. Circuit A1 connects to battery voltage and is protected by a 30 Amp fuse in the PDC. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3012 EGR Control Solenoid: Component Tests and General Diagnostics TESTING ELECTRICAL SOLENOID PORTION OF VALVE This is not to be used as a complete test of the EGR system. Electrical operation of the valve should be checked with the DRB or equivalent scan tool. Refer to the appropriate procedures. Replace solenoid if necessary, unit serviced only as an assembly Fig 4 EGR System TESTING VACUUM TRANSDUCER PORTION OF VALVE NOTE: The first part of this test will determine if the transducer diaphragm at the back-pressure side of the valve has ruptured or is leaking. The second part of the test will determine if engine vacuum (full-manifold) is flowing from the inlet to the outlet side of the valve. This is not to be used as a complete test of the EGR system. 1. Disconnect the rubber back-pressure hose from the fitting at the bottom of EGR valve (Fig. 4). 2. Connect a hand-held vacuum pump to this fitting. 3. Apply 10 inches of vacuum to this fitting. 4. If vacuum falls off, the valve diaphragm is leaking. 5. Replace the EGR valve assembly. Proceed to next step for further testing. 6. Remove the rubber hose at the vacuum inlet fitting (Fig. 4) on the EGR valve. 7. Connect a vacuum gauge to this disconnected hose. 8. Start the engine and bring to operating temperature. - Hold engine speed at approximately 1,500 rpm. 9. Check for steady engine vacuum (full-manifold) at this hose. 10. If engine vacuum (full-manifold) is not present, check vacuum line to engine and repair as necessary before proceeding to next step. 11. Reconnect the rubber hose to the vacuum inlet fitting (Fig. 4) on the EGR valve. 12. Disconnect the rubber hose at the vacuum outlet fitting (Fig. 4) on the EGR valve. 13. Connect a vacuum gauge to this fitting. 14. Disconnect the electrical connector (Fig. 4) at the valve control. - This will simulate an open circuit (no ground from the PCM) at the valve. 15. Start the engine and bring to operating temperature. 16. Hold the engine speed to approximately 2,000 rpm while checking for engine vacuum (full-manifold) at this fitting. - To allow full manifold vacuum to flow through the valve, exhaust back-pressure must be present at valve. - It must be high enough to hold the bleed valve in the transducer portion of the valve closed. - Have a helper momentarily (a second or two) hold a rag over the tailpipe opening to build some exhaust back-pressure while observing the Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3013 vacuum gauge. - Heavy gloves should be worn. CAUTION: Do not cover the tailpipe opening for an extended period of time as damage to components or overheating may result. 17. As temporary back-pressure is built, full manifold vacuum should be observed at the vacuum outlet fitting. - Without back-pressure, and engine at approximately 2,000 rpm, the gauge reading will be low. - This low reading is normal. - At idle speed, the gauge reading will be erratic. - This is also normal. 18. If full manifold vacuum is not present at the outlet fitting, but was present at the inlet fitting, replace the valve. NOTE: The EGR valve, valve control and attaching hoses are serviced as one assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Testing and Inspection > Page 3014 EGR Control Solenoid: Service and Repair Fig. 1 EGR System NOTE: If the EGR system operates incorrectly, replace the entire EGR valve and transducer together. The EGR valve and Electronic EGR Transducer (EET) are calibrated together. NOTE: The EGR valve and EET attach to the rear of the cylinder head (Fig. 1). REMOVAL 1. Disconnect vacuum supply tube from EET solenoid. 2. Disconnect electrical connector from solenoid. 3. Remove EGR tube to EGR valve screws. 4. Remove EGR valve mounting screws. Remove EGR valve and transducer. 5. Clean gasket surfaces. Discard old gaskets. If necessary, clean EGR passages. INSTALLATION 1. Loosely install EGR valve with new gaskets. 2. Finger tighten EGR tube fasteners. 3. Tighten EGR tube fasteners to 11 Nm (95 in lb) torque. 4. Tightening EGR valve mounting screws to 22 Nm (200 in lb) torque. 5. Connect vacuum supply tube to solenoid. 6. Attach electrical connector to solenoid. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications EGR Tube: Specifications EGR tube to intake manifold ................................................................................................................ ....................................................... 11 Nm (95 in lb) EGR tube to EGR valve ....................................................................................................................... ....................................................... 11 Nm (95 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 3018 EGR Tube: Service and Repair Fig. 1 EGR System Fig. 3 EGR Tube Stud Bolts NOTE: The EGR tube attaches to the intake manifold plenum below the throttle body and EGR valve (Fig. 1). REMOVAL 1. Remove screws attaching EGR tube to intake manifold (Fig. 3). 2. Remove EGR tube to EGR valve screws. 3. Remove EGR tube. Clean gasket surface on the EGR valve. Wipe clean the grommet on the intake manifold. NOTE: The rubber grommet that seals the EGR tube to intake manifold connection is reusable. INSTALLATION 1. Loosely install the EGR tube and fasteners. 2. Tighten the EGR tube to intake manifold plenum screws to 11 Nm (95 in. lbs) torque. 3. Tighten the EGR tube to EGR valve screws to 11 Nm (95 in lb) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications EGR Valve: Specifications EGR valve to cyl. head ........................................................................................................................ ...................................................... 22 Nm (200 in lb) EGR tube to EGR valve ....................................................................................................................... ....................................................... 11 Nm (95 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 3022 EGR Valve: Description and Operation PURPOSE To assist in the control of oxides of nitrogen (NOx) in engine exhaust, all engines are equipped with an exhaust gas recirculation system. The use of exhaust gas to dilute incoming air/fuel mixtures lowers peak flame temperatures during combustion, thus limiting the formation of NOx. OPERATION Exhaust gases are taken from the number four exhaust port through a hole in the end of the cylinder head. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 3023 EGR Valve: Testing and Inspection Fig 4 EGR System EGR VALVE LEAKAGE TEST This is not to be used as a complete test of the EGR system. If the engine will not idle, dies out on idle, or idle is rough or slow, the poppet valve (Fig. 4) at the base of the EGR valve may be leaking in the closed position. 1. The engine should be off for the following test. 2. Disconnect the rubber hose from the fitting (Fig. 4) at the top (vacuum motor) side of the EGR valve. a. Connect a hand-held vacuum pump to this fitting. b. Apply 15 inches of vacuum to the pump. c. Observe the gauge reading on the pump. d. If vacuum falls off, the diaphragm in the EGR valve has ruptured. e. Replace the EGR valve. Note: The EGR valve, valve control and attaching hoses are serviced as one assembly. f. Proceed to the next step. 3. A small metal fitting (back-pressure fitting) is located at the base of the EGR valve (Fig. 4). - A rubber back-pressure hose connects it to the back-pressure fitting on the EGR valve control. - Disconnect this rubber hose at the EGR valve fitting. 4. Remove the air cleaner housing from the throttle body 5. Using compressed air, and an air nozzle with a rubber tip, apply approximately 50 psi of regulated shop air to the metal back-pressure fitting on the EGR valve. 6. By hand, open the throttle to the wide open position. - Air SHOULD NOT BE HEARD emitting from the intake manifold while applying air pressure at the back-pressure fitting. 7. If air CAN BE HEARD emitting from the intake manifold, the poppet valve (Fig. 4) is leaking at the bottom of the EGR valve. - Replace the EGR valve. NOTE: The EGR valve, valve control and attaching hoses are serviced as one assembly. Do not attempt clean the old EGR valve. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 3024 EGR Valve: Service and Repair Fig.3 EGR System NOTE: If the EGR system operates incorrectly, replace the entire EGR valve and transducer together. The EGR valve and electrical transducer (EET) are calibrated together. NOTE: The EGR valve attaches to the rear of the cylinder head (Fig. 3). EGR transducer is attached to the air inlet duct. REMOVAL 1. Remove EGR transducer from air inlet duct. 2. Disconnect vacuum supply tube from EGR transducer solenoid. 3. Disconnect electrical connector from solenoid. 4. Remove air inlet duct. 5. Remove EGR tube to EGR valve screws. 6. Remove EGR valve mounting screws. Remove EGR valve and transducer. 7. Clean gasket surfaces. Discard old gaskets. If necessary, clean EGR passages. INSTALLATION 1. Loosely install EGR valve with new gaskets. 2. Finger tighten EGR tube fasteners. 3. Tighten EGR tube fasteners to 11 Nm (95 in lb) torque. 4. Tightening EGR valve mounting screws to 22 Nm (200 in lb) torque. 5. Install air inlet duct. 6. Connect vacuum supply tube to solenoid. 7. Attach electrical connector to solenoid. 8. Install EGR transducer onto air inlet duct. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation Positive Crankcase Ventilation: Description and Operation Intake manifold vacuum removes crankcase vapors and piston blow-by from the separator. Emissions pass through the PCV valve into the intake manifold plenum. The vapors become part of the calibrated air-fuel mixture, are burned and then expelled with the exhaust gases. The air cleaner supplies make up air when the engine does not have enough vapor or blow-by gases. NOTE: In this system, fresh air does not enter the crankcase. PCV VALVE The PCV valve contains a spring loaded plunger. The plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum. Fig. 7 Engine Off Or Engine Backfire - No Vapor Flow When the engine is not operating or during an engine backfire, the spring forces the plunger back against the seat. This prevents vapors from flowing through the valve (Fig. 7). Fig. 8 High Intake Manifold Vacuum - Minimal Vapor Flow When the engine is at idle or cruising, high manifold vacuum is present. At these times manifold vacuum is able to completely compress the spring and pull the plunger to the top of the valve (Fig. 8). In this position there is minimal vapor flow through the valve. Fig. 9 Moderate Intake Manifold Vacuum - Maximum Vapor Flow During periods of moderate intake manifold vacuum the plunger is only pulled part way back from the inlet. This results in maximum vapor flow through the valve (Fig. 9). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Page 3028 Positive Crankcase Ventilation: Testing and Inspection Fig.9 PVC Test-Typical WARNING: Apply parking brake and/or block wheels before performing any test or adjustment with the engine operating. With the engine idling, remove the PCV valve from its attaching point. If the valve is operating properly, a hissing noise will be heard and a strong vacuum felt when placing a finger over the valve inlet (Fig. 9). With the engine off, shake the valve. The valve should rattle when shaken. Replace the valve if it does not operate properly. Do not attempt to clean the PCV valve. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Typical -- SOHC Shown Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 3037 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 12 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) 6. Replace Pressure test port cap when finished releasing pressure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle Odometer <= 1,000 Miles ................................................................................ ............................................................................................. 550 - 1,300 rpm Odometer >= 1,000 Miles .................................................................................................................................................... ......................... 600 - 1,300 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3041 Idle Speed: Testing and Inspection Fig. 31 PCV Vacuum Nipple 1. Turn ignition key off. 2. Disconnect the PCV valve hose from the intake manifold nipple (Fig. 31). Cap the PCV vacuum nipple. Fig. 32 Purge Hose 3. Disconnect purge hose from the nipple on the throttle body (Fig. 32). Fig. 33 Orifice 6457 Attached To Purge Nipple 4. Use a piece of hose to attach Air Metering Orifice 6457 (0.125 in. orifice) or equivalent, to the purge nipple on the throttle body (Fig. 33). 5. Ensure that all accessories are off. 6. Connect the DRB or equivalent scan tool to the data link connector inside the passenger compartment. 7. Run engine in Park or Neutral until the cooling fan has cycled on and off at least once (180°F). 8. Using the DRB or equivalent scan tool, access Minimum Airflow Idle Speed. 9. The following will then occur: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3042 - Idle air control motor will fully close - Idle spark advance will become fixed - PCM will go open loop enriched - DRB or equivalent scan tool displays engine RPM 10. If idle RPM is within the range shown below, throttle body minimum airflow is set correctly. Odometer Reading Idle RPM Below 1,000 Miles 550 - 1,300 RPM Above 1,000 Miles 600 - 1,300 RPM 11. If idle RPM is above specifications, use the DRB or equivalent scan tool to check idle air control motor operation. If idle air control motor is OK, replace throttle body. If idle air flow is below specification, shut off the engine and clean the throttle body as follows: a. Remove the throttle body from engine. WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves, do not let Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash thoroughly after using cleaner. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when is closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 14. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 12. Shut off engine. 13. Remove Air Metering Orifice 6457 or equivalent. Install purge hose. 14. Remove cap from PCV valve. Connect hose to PCV valve. 15. Remove DRB or equivalent scan tool. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Accelerator Pedal: Specifications Accelerator Pedal to Dash Nuts 12 Nm (105 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 3046 Accelerator Pedal: Service and Repair Fig. 35 Accelerator Pedal and Throttle Cable-Front View Fig. 36 Accelerator Pedal and Throttle Cable-Rear View CAUTION: When servicing the accelerator pedal, throttle cable or speed control cable, do not damage or kink the core wire inside the cable sheathing. REMOVAL 1. Working from the engine compartment, remove the throttle control shield. 2. Hold the throttle body throttle lever in the wide open position. - Remove the throttle cable from the throttle body cam. 3. From inside the vehicle, hold up the pedal and remove the cable retainer and throttle cable from the upper end of the pedal shaft (Fig. 35) and (Fig. 36). 4. Working from the engine compartment, remove nuts from accelerator pedal attaching studs (Fig. 35). - Remove assembly from vehicle. INSTALLATION 1. Position accelerator pedal assembly on dash panel. Install retaining nuts. - Tighten retaining nuts to 12 Nm (105 in lb) torque. 2. From inside the vehicle, hold up the pedal and install the throttle cable and cable retainer in the upper end of the pedal shaft. 3. From the engine compartment hold the throttle body lever in the wide open position and install the throttle cable. - Install the throttle control shield. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Fig. 104 Air Intake Duct Fig. 105 Removal/Installation of Air Inlet Duct NOTE: Neon vehicles do not use a heated air inlet system. The PCM adjusts fuel injector pulse width and ignition timing to compensate for different ambient temperatures. NOTE: The air cleaner attaches to a bracket on the rear of the cylinder head. An ambient air duct supplies underhood air for the engine. REMOVAL 1. Remove air intake tube (Fig. 104) from air cleaner and intake manifold (Fig. 105). Fig. 106 Removal/Installation Air Cleaner Front Housing and Element 2. Tighten clasps on top of air cleaner housing. Rotate front of housing forward then lift front away from air cleaner housing (Fig 106). 3. Remove air cleaner element from front housing (Fig. 106). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 3051 INSTALLATION 1. Install air cleaner element into front housing. 2. Rotate front of housing forward then lower into place and locate tabs in slots. - Fasten clasps on top of air cleaner housing. - Install air intake duct at air cleaner and intake manifold. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Engine - High Driveability Index Fuels Fuel: Technical Service Bulletins Engine - High Driveability Index Fuels NO: 14-08-97 GROUP: Fuel DATE: Nov. 21, 1997 SUBJECT: Poor Driveability With High DI (Driveability Index) Fuel MODELS: 1996 - 1998 (AB) Ram Van/Wagon 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1996 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (PL) Neon 1997 (PR) Prowler 1996 - 1998 (SR) Viper Roadster/Coupe 1997 - 1998 (TJ) Wrangler 1996 - 1998 (XJ) Cherokee 1995 - 1998 (ZJ) Grand Cherokee SYMPTOM/CONDITION: Long cold start times, warm-up sags, hesitations, and driveway die outs. These symptoms are most noticeable and severe at moderate ambient temperatures between 4 - 27 degrees C (40 - 80 degrees F). DISCUSSION: Gasoline with a high Driveability Index (DI) can cause the above described symptoms. DI is a measure of the gasolines total volatility, or tendency to vaporize completely. A high DI number is less volatile than a low DI number. Most premium gasoline sold in the U.S. has a higher (worse) DI index than regular or mid-grade gasoline. Use of premium gasoline is NOT recommended for vehicles designed to run on 87 (R+M)/2 regular or 89 (R+M)/2 midgrade gasoline. High DI gasolines also cause higher emissions for the same reasons they cause driveability problems. For vehicles that require an octane rating of 91 (R+M)/2, premium is recommended, or possibly required. Using premium fuel with a higher than recommended octane rating is not recommended. Owners who experience fuel related cold start and warm up driveability problems should try a gasoline with the recommended octane rating or different brands of gasoline until they find one that provides good performance. The octane quality of gasoline is only a measure of its resistance to spark knock. The use of higher than recommended octane gasoline under normal operating conditions does NOT improve startability, idle quality, fuel economy, driveability, acceleration, engine durability, or emissions. In fact, most higher octane gasolines available in the U.S. have higher DI values than regular gasoline. Customers are most likely to experience poor driveability with premium gasoline than with regular. Some vehicles, such as Viper, Prowler, 5.9L Grand Cherokee, 2.0L Turbo Talon, and 2.0L DOHC Neon have been specifically designed to take advantage of higher octane. These vehicles may have higher compression ratios, and/or more aggressive spark calibrations which provide optimum performance with the specified higher octane. However, other vehicles which are not specifically designed and calibrated to take advantage of higher octane will not benefit from higher octane. Some vehicles may experience light spark knock in situations such as trailer towing or climbing steep sustained grades. Light knock or "ping" under these conditions is not harmful. However, if the customer is concerned about light knock under these circumstances, the use of 89 (R+M)/2 or even 91 (R+M)/2 premium gasoline may be temporarily warranted. If a vehicle is experiencing heavy spark knock on gasoline with its designed octane rating, this may be an indication of excessive combustion chamber deposits, or some other problem. Combustion chamber deposits can be removed with Mopar Combustion Chamber Conditioner p/n 04318001. Standard diagnostic procedures may help in identifying other potential causes of excessive knock. Some gasoline marketers may advertise that their premium gasoline contains extra detergent additives. Under provisions of the Clean Air Act, ALL gasoline sold in the U.S. must contain effective deposit control additives. Nevertheless, if fuel injector or intake valve deposits are suspected of Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Engine - High Driveability Index Fuels > Page 3056 contributing to poor performance, occasional use of Mopar Fuel Injector Clean Up p/n 04549613 is a much less expensive way to maintain engine cleanliness than regular use of premium gasoline. The charts (Figures 1 & 2) show the negative effects of high DI fuel as related to customer satisfaction. If fuel quality is suspected in causing a customers driveability concern, your zone technical office may be able to provide direction on procedures for fuel sample analysis. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 3057 Fuel: Specifications FUEL REQUIREMENTS The vehicle is designed to meet all emission regulations and provide excellent fuel economy when using high quality unleaded gasoline having a minimum octane rating of 87. The vehicle will operate on fuels ranging from regular unleaded having a minimum posted octane of 87 to premium unleaded with a minimum posted octane of 91. However, mid-grade unleaded fuel with a minimum octane rating of 89 is recommended. The use of premium unleaded gasoline will further improve performance. If the vehicle develops occasional light spark knock (ping) at low engine speeds this is not harmful. However; continued heavy spark knock at high speeds can cause damage and should be corrected immediately. Engine damage as a result of heavy spark knock operation may not be covered by the new vehicle warranty. In addition to using unleaded gasoline with the proper octane rating, those that contain detergents, corrosion and stability additives are recommended. Using gasoline that has these additives will help improve fuel economy, reduce emissions, and maintain vehicle performance. Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. If you experience these problems, try another brand of gasoline before considering service for the vehicle. ADDITIVES & OXYGENATE BLENDS Additives - The use of gasoline containing detergents, corrosion and stability additives is recommended, as these additives will improve fuel economy, reduce emissions, and maintain vehicle performance. Fuel Quality - Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. If you experience these problems, try another brand of gasoline before considering service for the vehicle. Pinging/Knocking - Light knock at low engine speeds is not harmful to your engine. However, continued heavy spark knock at high speeds can cause damage and should be reported to your dealer immediately. CAUTION: Engine damage resulting from operating with a heavy spark knock may not be covered by the new vehicle warranty. GASOLINE/OXYGENATE BLENDS Ethanol - (Ethyl or Grain Alcohol) properly blended, is used as a mixture of 10 percent ethanol and 90 percent gasoline. Gasoline blended with ethanol may be used in your vehicle. Methanol - (Methyl or Wood Alcohol) is used in a variety of concentrations when blended with unleaded gasoline. You may find fuels containing 3 percent or more methanol along with other alcohols called cosolvents. CAUTION: Do not use gasoline containing Methanol. Use of methanol/gasoline blends may result in starting and driveability problems and damage critical fuel system components. Problems that are the result of using methanol/gasoline blends may not be covered by the new vehicle warranty. CLEAN AIR GASOLINE MTBE/ETBE - Many gasoline are now being blended that contribute to cleaner air, especially in those areas of the country where pollution levels are high. These new blends provide a cleaner burning fuel and some are referred to as reformulated gasoline.. MTBE (Methyl Tertiary Butyl Ether) blends are a mixture of unleaded gasoline and up to 15 percent MTBE. Gasoline blended with MTBE may be used in your vehicle. ETBE (Ethyl Tertiary Butyl Ether) blends are a mixture of unleaded gasoline and up to up to 17 percent ETBE. Gasoline blended with ETBE may be used in your vehicle. ADDITIVE CAUTION: Many materials intended for gum and varnish removal may contain active solvents or similar ingredients that can be harmful to fuel system gasket and diaphragm materials. Indiscriminate use of fuel system cleaning agents should be avoided. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation Fuel Filler Cap: Description and Operation Fig. 4 Pressure Vacuum Filler Cap WARNING: Remove fuel filler tube cap to relieve tank pressure before removing or repairing fuel system components. PURPOSE A pressure-vacuum relief cap seals the fuel tank (Fig. 4). The loss of any fuel or vapor out of the filler tube neck is prevented by the use of a safety filler cap. OPERATION Tightening the cap on the fuel filler tube forms a seal between them. The relief valves in the cap are a safety feature. They prevent possible excessive pressure or vacuum in the tank. Excessive fuel tank pressure could be caused by a malfunction in the system or damage to the vent lines. The seal between the cap and filler tube breaks when the cap is removed. Breaking the seal relieves fuel tank pressure. Pressure Release The cap releases only under significant pressure 10.9 to 13.45 kPa (1.58 to 1.95 psi). Vacuum Release The vacuum release for all gas caps is between 0.97 and 2.0 kPa (0.14 and 0.29 psi). Replacement If the filler cap needs replacement, only use an original equipment or equivalent unit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3065 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 12 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) 6. Replace Pressure test port cap when finished releasing pressure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Injector Circuit Test Revisions Fuel Injector: Technical Service Bulletins Fuel System - Injector Circuit Test Revisions NUMBER: 26-05-98E GROUP: Miscellaneous DATE: May, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.0L, 2.4L, 2.5L, 3.3L, 3.5L Passenger Car Powertrain Diagnostic Manual Publication Number 81-699-96040 DESCRIPTION OF CHANGES Revision to the injector circuit test Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Injector Circuit Test Revisions > Page 3070 153 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications Injector Resistance .............................................................................................................................. .......................................... 12 ohms at 20 ° C (68 ° F) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 3073 Fuel Injector: Pressure, Vacuum and Temperature Specifications Information not supplied by the manufacturer. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3074 Injector Connector -- Typical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Fuel Injectors Description Fuel Injector: Description and Operation Fuel Injectors Description Fig. 4 Fuel Injector Fig. 5 Fuel Injector Location-Typical OPERATION The fuel injectors are 12 ohm electrical solenoids (Fig. 4). The injector contains a pintle that closes off an orifice at the nozzle end. When electric current is supplied to the injector the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is developed in the shape of a hollow cone. The spraying action atomizes the fuel, adding it to the air entering the combustion chamber. The injectors are positioned in the intake manifold with the nozzle ends directly above the intake valve port (Fig. 5). CIRCUIT OPERATION Circuit A14 is a bus bar in the Power Distribution Center (PDC), and connects to battery voltage. The contact side of the Automatic Shut Down ( ASD) relay connects circuit A14 and circuit A142. A 20 Amp fuse in the PDC protects circuits A14 and A142. Circuit A14 also supplies voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) controls the ground circuit for the coil side of the ASD relay on circuit K51. Circuit K51 connects to cavity 67 of the PCM connector. Circuit A142 supplies voltage for the fuel injectors. The PCM controls the ground circuit of each injector. Circuit K11 is the ground circuit for Injector #1. Circuit K11 connects to cavity 13 of the PCM. - Circuit K12 is the ground circuit for Injector #2. Circuit K12 connects to cavity 17 of the PCM. - Circuit K13 is the ground circuit for Injector #3. Circuit K13 connects to cavity 7 of the PCM. - Circuit K14 is the ground circuit for Injector #4. Circuit K14 connects to cavity 16 of the PCM. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Fuel Injectors Description > Page 3077 Fuel Injector: Description and Operation Injector Control Circuit Trouble Code Name of Code: Injector Control Circuit When Monitored: With battery voltage greater than 12 volts, the auto shutdown relay energized, injector pulse width less than 10 ms, and engine speed less than 3,000 rpm. Set Condition: This trouble code takes 0.64 to 10.0 seconds to set when no inductive kick is sensed 0.18 ms after injector turn off, and with no other injectors on. Theory of Operation: Fuel injectors are high-impedance solenoids controlled by the PCM. Battery voltage is supplied by the ASD relay. The injector on time (pulse width) is controlled by the amount of time the PCM grounds the injector control circuit. By varying this time, more or less fuel is allowed to flow through the injector. Possible Causes: - Open or shorted injector driver circuit - Open injector - Open ASD supply at injector - PCM failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Helpful Information Fuel Injector: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, ASD relay, generator, and the upstream and downstream heated oxygen sensors. The PCM controls the ground circuit for each of the components powered by circuit A142. The injectors operate in sequence. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Helpful Information > Page 3080 Fuel Injector: Testing and Inspection Resistance Test Related Images Check resistance between the injector terminals. Resistance should be between 10 and 16 ohms. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Helpful Information > Page 3081 Fuel Injector: Testing and Inspection Diagnostic Chart Fuel Injector Diagnosis For fuel injector diagnosis, refer to the Fuel Injector Diagnosis charts. For poor fuel economy diagnosis or engine miss also consider transmission problems. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 3082 Fuel Injector: Service and Repair Fig. 27 Fuel Rail and Injectors REMOVAL 1. Disconnect negative cable from battery. 2. Release fuel system pressure. 3. Disconnect fuel supply tube from rail. 4. Disconnect electrical connectors from fuel injectors (Fig. 27). 5. Remove fuel rail mounting screws. 6. Lift rail off of intake manifold. Cover the fuel injector openings in the intake manifold. Fig. 28 Fuel Injector Retainer 7. Remove fuel injector retainer (Fig. 28). Fig. 29 Fuel Injector 0-Rings 8. Pull injector out of fuel rail. Replace fuel injector 0-rings (Fig. 29). INSTALLATION 1. Apply a light coating of clean engine oil to the upper 0-ring. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 3083 2. Install injector in cup on fuel rail. 3. Install retaining clip. 4. Apply a light coating of clean engine oil to the 0-ring on the nozzle end of each injector. 5. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail mounting screws to 22.5 Nm ± 3 Nm (200 ± 30 in lb). 6. Attach electrical connectors to fuel injectors. 7. Conned fuel supply tube to fuel rail. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation Fuel Line Coupler: Description and Operation Fig 13 Plastic Retainer Type Fitting Different types of quick-connect fittings are used to attach various fuel system components. These are: a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. CAUTION: The interior components (O-rings, spacers) of quick connect fittings are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. Fuel tubes connect fuel system components with plastic quick-connect fuel fittings. The fitting contains non-serviceable O-ring seals. CAUTION: Quick-connect fittings are not serviced separately. Do not attempt to repair damaged quick-connect fittings or fuel tubes. Replace the complete fuel tube/quick-connect fitting assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Plastic Retaining Ring Type Fitting Fuel Line Coupler: Service and Repair Plastic Retaining Ring Type Fitting Fig 13 Plastic Retainer Type Fitting NOTE: This type of fitting can be identified by the use of a full-round plastic retainer ring (Fig. 13) usually black in color. WARNING: The fuel system is under a constant pressure (even with the engine off). Before servicing any fuel system hoses, fittings or lines, the fuel system pressure must be released. Perform Fuel Pressure Release procedure. CAUTION: The interior components (O-rings, spacers, retainers) of this type of quick-connect fitting are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. DISCONNECTION/CONNECTION 1. Disconnect negative battery cable from the battery. 2. Perform the fuel pressure release procedure. 3. Clean the fitting of any foreign material before disassembly. 4. To release the fuel system component from the quick-connect fitting: firmly push the fitting towards the component being serviced while firmly pushing the plastic retaining ring into the fitting (Fig. 13) With the plastic ring depressed, pull the fitting from the component. - The plastic retainer ring must be pressed squarely into the fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on the shoulder of the plastic retainer ring to aid in disconnection. 5. After disconnection, the plastic retainer ring will remain with the quick-connect fitting connector body. 6. Inspect fitting connector body, plastic retainer ring and fuel system component for damage. - Replace as necessary. 7. Prior to connecting the quick-connect fitting to component being serviced, check condition of fitting and component. - Clean the parts with a lint-free cloth. - Lubricate them with clean engine oil. 8. Insert the quick-connect fitting into the component being serviced until a click is felt. 9. Verify a locked condition by firmly pulling on fuel tube and fitting ( 15-30 lbs). 10. Connect negative battery cable to battery. 11. Start engine and check for leaks. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Plastic Retaining Ring Type Fitting > Page 3089 Fuel Line Coupler: Service and Repair Quick Connect Fittings Fig. 14 Plastic Quick-Connect Fitting/Fuel Tube Connection WARNING: Release fuel system pressure before disconnecting a quick-connect fittings. Refer to the fuel pressure release procedure. NOTE: When disconnecting a quick-connect fitting, the retainer will remain on the fuel tube nipple. REMOVAL 1. Disconnect negative cable from battery. 2. Perform Fuel Pressure Release Procedure. 3. Squeeze retainer tabs together and pull fuel tube/quick-connect fitting assembly off of fuel tube nipple. The retainer will remain on fuel tube. CAUTION: Never install a quick-connect fitting without the retainer being either on the fuel tube or already in the quick-connect fitting. In either case, ensure the retainer locks securely into the quick-connect fitting by firmly pulling on fuel tube and fitting to ensure it is secured. INSTALLATION 1. Using a clean lint free cloth clean the fuel tube nipple and retainer. 2. Prior to connecting the fitting to the fuel tube, coat the fuel tube nipple with clean 30 weight engine oil. 3. Push the quick-connect fitting over the fuel tube until the retainer seats and a click is heard. 4. The quick-connect fitting has windows in the sides of the casing. - When the fitting completely attaches to the fuel tube, the retainer locking ears and the fuel tube shoulder are visible in the windows. - If they are not visible, the retainer was not properly installed (Fig. 14). - Do not rely upon the audible click to confirm a secure connection. CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized for either 7 minutes, until the test is stopped, or until the ignition switch is turned to the Off position. 5. Use the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation Fuel Pressure Regulator: Description and Operation Fig. 2 Side View-Filter/Regulator A combination fuel filter and fuel pressure regulator is used on all gas powered engines. It is located on the top of the fuel pump module. A separate frame mounted fuel filter is not used. Fuel Pressure Regulator Operation: The pressure regulator is a mechanical device that is calibrated to maintain fuel system operating pressure of approximately 338 kPa (49 psi) at the fuel injectors. It contains a diaphragm, calibrated springs and a fuel return valve. The internal fuel filter (Fig. 2) is also part of the assembly Fuel is supplied to the filter/regulator by the electric fuel pump through an opening tube at the bottom of filter/regulator. The fuel pump module contains a check valve to maintain some fuel pressure when the engine is not operating. This will help to start the engine. If fuel pressure at the pressure regulator exceeds approximately 49 psi, an internal diaphragm closes and excess fuel pressure is routed back into the tank through the pressure regulator. A separate fuel return line is not used with any gas powered engine. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 3093 Fuel Pressure Regulator: Service and Repair Fig. 18 Locking Spring Tab WARNING: The fuel system is under a constant pressure, even with engine off before servicing the fuel filter/fuel pressure regulator, the fuel system pressure must be released. NOTE: The fuel filter/fuel pressure regulator is located on the top of fuel pump module. Fuel pump module removal is not necessary. REMOVAL 1. Raise vehicle on hoist. 2. Disconnect fuel supply line at the Filter/Regulator nipple. 3. Depress locking spring tab on side of Fuel/Regulator (Fig. 18) and rotate 9O° counter-clockwise and pull out. NOTE: Make sure that the upper and lower 0-rings are on the Filter/Regulator assembly, and lightly lubricate the 0-rings with engine oil. Fig. 19 Spring Tab In Locating Slot INSTALLATION 1. Insert filter/regulator into the opening in the fuel pump module, align the two hold down tabs with the flange. 2. While applying downward pressure, rotate the Filter/Regulator clockwise until the the spring tab engages the locating slot (Fig. 19). 3. Connect the fuel line to the Filter/Regulator. 4. Lower vehicle from hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Locations Typical -- SOHC Shown Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Typical -- SOHC Shown Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Component Locations Fuel Pump Relay: Component Locations Power Distribution Center (Top) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Component Locations > Page 3106 Fig. 15 Power Distribution Center (PDC) The fuel pump relay is located in the Power Distribution Center (PDC). The inside top of the PDC cover has a label showing relay and fuse location. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Component Locations > Page 3107 Fuel Pump Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Fuel Pump Relay Connector Fuel Pump Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Fuel Pump Relay Connector > Page 3110 Fuel Pump Relay: Diagrams Power Distribution Power Distribution Center (Bottom) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Fuel Pump Relay Connector > Page 3111 Power Distribution Center (Top) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Description and Operation > Fuel Pump Relay Operation Fuel Pump Relay: Description and Operation Fuel Pump Relay Operation NAME OF CODE: Fuel Pump Relay Control Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the fuel pump relay control circuit. THEORY OF OPERATION: The fuel pump relay controls the 12-volt source to the fuel pump. If the vehicle is equipped with a power distribution center, the relay is located in the Power Distribution Center (PDC). One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the RUN or CRANK position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the fuel pump relay control circuit ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Fuel pump relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Description and Operation > Fuel Pump Relay Operation > Page 3114 Fuel Pump Relay: Description and Operation Fuel Pump Relay Control Circuit Trouble Code Name of Code: Fuel Pump Relay Control Circuit When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: An open or shorted condition is detected in the fuel pump relay control circuit. Theory of Operation: The fuel pump relay controls the 12-volt source to the fuel pump. If the vehicle is equipped with a power distribution center, the relay is located in the PDC. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "run position". The circuit is completed when the other side of the relay coil is grounded by the powertrain control module. The PCM grounds the relay when the ignition switch is in either the run or crank position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the fuel pump relay control circuit ground. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - Fuel pump relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Description and Operation > Page 3115 Fuel Pump Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30 is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85 -- The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86 supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A -- When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87 When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Description and Operation > Page 3116 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications Fuel Rail: Specifications Fuel Rail Bolts 23 Nm (195 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3120 Fuel Rail: Description and Operation Fig. 3 Fuel Rail-Typical The fuel rail supplies the necessary fuel to each individual fuel injector and is mounted to the intake manifold (Fig. 3). The fuel pressure regulator is no longer mounted to the fuel rail on any engine. It is now located on the fuel tank mounted fuel pump module. The fuel rail is not repairable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair Fuel Filler Hose: Service and Repair Fig. 33 Fuel Filler Neck REMOVAL 1. Loosen fuel filler tube cap. 2. Remove fuel filler neck screws (Fig. 33). 3. Disconnect fuel fill vapor tube. 4. Disconnect fuel filler tube from fuel tank. Remove filler neck. INSTALLATION 1. Reverse for installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > General Description Fuel Gauge Sender: Description and Operation General Description Fig. 10 Level Sensor Diagnosis OPERATION The fuel gauge sending unit is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and two variable resistors (tracks). These two tracks are used to send two different electrical signals. One is used for fuel gauge operation and the other is for OBD II emission requirements. Track 1 fuel gauge operation: As the fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge on the instrument panel to read full. As the fuel level decreases, the float and arm move down. This increases the sending unit resistance, causing the fuel gauge on the instrument panel to read empty Track 2-OBD II emission requirements: A variable voltage signal is sent to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes if the fuel level in the tank is less than 15 percent of its rated capacity. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > General Description > Page 3129 Fuel Gauge Sender: Description and Operation Related Trouble Codes and Set Conditions Fuel Level Sending Unit Volts Too High Name of Code: Fuel Level Sending Unit Volts Too High When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes above a calculated value. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel systems monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Open sensor signal circuit - Fuel level sending unit failure - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Fuel Level Sending Unit Volts Too Low Name of Code: Fuel Level Sending Unit Volts Too Low When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes below 0.10 volts. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel system monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Sensor signal circuit shorted to ground - Fuel level sending unit failure - Loss of fuel ignition switch output voltage - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Sending Unit Operation Check Fuel Gauge Sender: Testing and Inspection Sending Unit Operation Check When a problem occurs with a cluster gauge check for a defective sending unit or wiring. Do this before disassembling the cluster. 1. Sending units and wiring can be checked by grounding the connector leads at the sending unit in the vehicle. 2. With the ignition in the ON position, a grounded input will cause the fuel or temperature gauge to read at or above maximum. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 3132 Fuel Gauge Sender: Testing and Inspection Sending Unit Voltage Check Fig. 1 Fuel Guage Test Terminal 1. Remove the fuel gauge electrical harness. 2. Connect 12 volt test light to the fuel gauge and ground terminal. 3. Turn ignition to On position and proceed as follows: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 3133 a. If test light illuminates and pointer of gauge does not swing, replace fuel gauge. b. If test light illuminates and pointer of gauge swings, replace fuel gauge unit. c. If test light does not light and pointer of gauge does not swing, check the electrical harness for kinks chaffing and broken wires. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 3134 Fuel Gauge Sender: Testing and Inspection Sending Unit Resistance Check Fig. 10 Level Sensor Diagnosis This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. To test the level sensor, connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector. Move the float lever to the positions shown in the resistance chart. Record the resistance at each point. Replace the level sensor if the resistance is not within specifications. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 3135 Fuel Gauge Sender: Service and Repair Fig. 21 Fuel Pump/Level Sensor Electrical Connector NOTE: Remove fuel pump module prior to beginning this procedure. REMOVAL 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector. Fig. 22 Wire Terminal Locking Wedge 2. Pull off blue locking wedge. Fig. 23 Wire Terminal Locking Finger 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 3136 Fig. 24 Removing Wires From Connector 4. Push level sensor signal and ground terminals out of the connector. Fig. 25 Loosening Level Sensor 5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Fig. 26 Level Sensor Removal/Installation 6. Push level sensor down slightly. - Ensure tab at bottom of sensor locks in place. 7. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 8. Install locking wedge on connector. 9. Push connector up into bottom of fuel pump module electrical connector. 10. Install fuel pump module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Specifications Fuel Tank Mounting Straps: Specifications Fuel Tank Straps torque = 23 Nm (250 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Description and Operation Fuel Tank Unit: Description and Operation Fig. 1 Fuel Pump Module NOTE: The fuel pump module is installed in the top of the fuel tank (Fig. 1). The fuel pump module contains the following: Electric fuel pump - Fuel pump reservoir - Inlet strainer - Fuel filter/pressure regulator - Fuel gauge sending unit - Fuel supply line connection The inlet strainer, fuel pressure regulator and fuel level sensor are the only serviceable items. If the fuel pump requires service, replace the fuel pump module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Description and Operation > Page 3143 Fuel Tank Unit: Service and Repair Fig. 16 Fuel Pump Module Removal WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. never smoke while servicing the vehicle. REMOVAL 1. Drain the fuel. WARNING: The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed. 2. Disconnect fuel line from fuel pump module by depressing quick connect retainers with thumb and fore finger. 3. Slide fuel pump module electrical connector lock to unlock. 4. Disconnect the electrical connection from the fuel pump module by pushing down on connector retainer and pulling connector off of module. 5. Use a transmission jack to support the fuel tank. remove bolts from fuel tank straps. 6. Lower tank slightly Fig. 17 Fuel Tank Locknut 7. Use Special Tool 6856 to remove fuel pump module locknut (Fig. 17). 8. Remove fuel pump and 0-ring seal from tank. Discard old seal. INSTALLATION 1. Wipe seal area of tank clean and place a new seal in position in the tank opening. 2. Position fuel pump in the tank. Make sure the alignment tab on the underside of the fuel pump module flange sits in the notch on the fuel tank. 3. Position the locknut over the fuel pump module. 4. Tighten the locknut using Special Tool 6856 to 55 Nm (40.5 ft lb) (Fig. 17). CAUTION: Over tightening the pump lock ring may result in a leak. 5. Fill fuel tank. Check for leaks. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications IAC Motor-To-Throttle Body Bolts 7 Nm (60 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3147 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3148 Idle Air Control Motor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3149 Idle Speed/Throttle Actuator - Electronic: Description and Operation THEORY OF OPERATION: The idle air control (IAC) motor is used by the Powertrain Control Module (PCM) to help regulate idle speed. The motor controls the amount of air allowed to bypass the throttle blade. The PCM controls the motor using four driver circuits to position the stepper motor. CIRCUIT OPERATION The Powertrain Control Module (PCM) operates the Idle Air Control (IAC) motor through 4 circuits K39, K40, K59, and K60. Each circuit connects to separate cavities in the PCM connector. Circuit K39 connects to cavity 57 of the PCM connector. - Circuit K40 connects to cavity 48 of the PCM connector. - Circuit K59 connects to cavity 58 of the PCM connector. - Circuit K60 connects to cavity 49 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3150 Idle Speed/Throttle Actuator - Electronic: Service and Repair Fig. 95 Servicing Idle Air Control Motor CAUTION: When servicing throttle body components, always reassemble components with new 0-rings and seals where applicable. Never use lubricants on 0-rings or seals, damage may result. If assembly of component is difficult, use water to aid assembly. Use care when removing hoses to prevent damage to hose or hose nipple. REMOVAL 1. Disconnect negative cable from battery 2. Remove electrical connector from idle air control motor and throttle position sensor. 3. Remove the EVAP purge hose from the throttle body. 4. Remove throttle body. 5. Remove idle air control motor mounting screws (Fig. 95). 6. Remove motor from throttle body Ensure the 0-ring is removed with the motor. INSTALLATION 1. The new idle air control motor has a new 0-ring installed on it. - If pintle measures more than 1 inch (25 mm) it must be retracted. - Use the DRB Idle Air Control Motor Open/Close Test to retract the pintle (battery must be connected). 2. Carefully place idle air control motor into throttle body 3. Install mounting screws. Tighten screws to 7 Nm (60 in lb) torque. 4. Install throttle body. 5. Connect electrical connector to idle air control motor and throttle position sensor. 6. Connect the EVAP purge hose to the throttle body nipple. 7. Connect negative cable to battery. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig. 15 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3154 Power Distribution Center (Top) The relay is located in the Power Distribution Center (PDC). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector Auto Shutdown Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector > Page 3157 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Power Distribution Center (Bottom) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector > Page 3158 Power Distribution Center (Top) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 3159 Automatic Shut Down (ASD) Relay: Description and Operation Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. CIRCUIT OPERATION The Automatic Shut Down (ASD) relay is located in the Power Distribution Center (PDC). Power for the coil and contact side of the relay is supplied on circuit A14. This circuit is HOT at all times and protected by a 20 Amp fuse located in the PDC. The Powertrain Control Module (PCM) controls the ground path for the coil side of the relay on circuit K51. This circuit connects to cavity 67 of the PCM. When the PCM supplies the ground path on circuit K51 the contacts in the relay CLOSE connecting circuits A14 and A142. The A142 circuit is spliced and supplies power to the generator, fuel injectors, PCM, ignition coil, and heated oxygen sensors. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 Amp fuse located in the PDC. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 3162 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 3163 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Component Locations Fuel Pump Relay: Component Locations Power Distribution Center (Top) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Component Locations > Page 3169 Fig. 15 Power Distribution Center (PDC) The fuel pump relay is located in the Power Distribution Center (PDC). The inside top of the PDC cover has a label showing relay and fuse location. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Component Locations > Page 3170 Fuel Pump Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Fuel Pump Relay Connector Fuel Pump Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Fuel Pump Relay Connector > Page 3173 Fuel Pump Relay: Diagrams Power Distribution Power Distribution Center (Bottom) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Fuel Pump Relay Connector > Page 3174 Power Distribution Center (Top) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Fuel Pump Relay Operation Fuel Pump Relay: Description and Operation Fuel Pump Relay Operation NAME OF CODE: Fuel Pump Relay Control Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the fuel pump relay control circuit. THEORY OF OPERATION: The fuel pump relay controls the 12-volt source to the fuel pump. If the vehicle is equipped with a power distribution center, the relay is located in the Power Distribution Center (PDC). One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the RUN or CRANK position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the fuel pump relay control circuit ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Fuel pump relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Fuel Pump Relay Operation > Page 3177 Fuel Pump Relay: Description and Operation Fuel Pump Relay Control Circuit Trouble Code Name of Code: Fuel Pump Relay Control Circuit When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: An open or shorted condition is detected in the fuel pump relay control circuit. Theory of Operation: The fuel pump relay controls the 12-volt source to the fuel pump. If the vehicle is equipped with a power distribution center, the relay is located in the PDC. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "run position". The circuit is completed when the other side of the relay coil is grounded by the powertrain control module. The PCM grounds the relay when the ignition switch is in either the run or crank position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the fuel pump relay control circuit ground. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - Fuel pump relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Page 3178 Fuel Pump Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30 is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85 -- The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86 supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A -- When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87 When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Page 3179 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig. 15 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3183 Power Distribution Center (Top) The relay is located in the Power Distribution Center (PDC). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector Auto Shutdown Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector > Page 3186 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Power Distribution Center (Bottom) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > ASD Relay Connector > Page 3187 Power Distribution Center (Top) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 3188 Automatic Shut Down (ASD) Relay: Description and Operation Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. CIRCUIT OPERATION The Automatic Shut Down (ASD) relay is located in the Power Distribution Center (PDC). Power for the coil and contact side of the relay is supplied on circuit A14. This circuit is HOT at all times and protected by a 20 Amp fuse located in the PDC. The Powertrain Control Module (PCM) controls the ground path for the coil side of the relay on circuit K51. This circuit connects to cavity 67 of the PCM. When the PCM supplies the ground path on circuit K51 the contacts in the relay CLOSE connecting circuits A14 and A142. The A142 circuit is spliced and supplies power to the generator, fuel injectors, PCM, ignition coil, and heated oxygen sensors. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 Amp fuse located in the PDC. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 3191 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 3192 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Description and Operation Rollover Valve: Description and Operation All models pass a full 360 degree rollover test without fuel leakage. To accomplish this, fuel and vapor flow controls are required for all fuel tank connections. All Neon vehicles have two rollover valves. One in the fuel filler tube and the other on the top of the fuel tank. The valves prevent fuel flow through the fuel tank vent valve hoses should the vehicle rollover. An evaporation control system is connected to the rollover valve(s) to reduce emissions of fuel vapors into the atmosphere. When fuel evaporates from the fuel tank, vapors pass through vent hoses or tubes to a charcoal canister where they are temporarily held. When the engine is running, the vapors are drawn into the intake manifold. Certain models are also equipped with a self-diagnosing system using a Leak Detection Pump (LDP). Refer to Emission Control Systems for additional information. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Service and Repair > Fuel Filler Tube Rollover Valve Replacement Rollover Valve: Service and Repair Fuel Filler Tube Rollover Valve Replacement Fig 34 Fuel Filler Tube Rollover Valve NOTE: The rollover valve is mounted in the fuel filler tube (Fig. 34). REMOVAL 1. To release fuel tank pressure, remove the fuel filler tube cap. 2. Disconnect vapor tube from rollover valve. 3. Using a straight screwdriver, pry the valve out of the grommet in the fuel filler tube. INSTALLATION 1. Apply a light coating of power steering fluid to the grommet. 2. Install valve in grommet. 3. Attach vapor tube to valve. 4. Install fuel filler tube cap. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Service and Repair > Fuel Filler Tube Rollover Valve Replacement > Page 3198 Rollover Valve: Service and Repair Fuel Tank Rollover Valve Replacement REMOVAL 1. To release fuel tank pressure, remove the fuel filler tube cap. 2. Remove fuel tank. Refer to procedure. 3. Disconnect vapor tube from rollover valve. 4. Using a straight screwdriver, pry the valve out of the grommet in the fuel filler tube. INSTALLATION 1. Apply a light coating of power steering fluid to the grommet. 2. Install valve in grommet. 3. Attach vapor tube to valve. 4. Install fuel tank. Refer to procedure. See: Fuel Tank/Service and Repair/Fuel Tank Replacement 5. Install fuel filler tube cap. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3204 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3205 Throttle Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3206 Throttle Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3207 Throttle Position Sensor: Description and Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS mounts to the throttle body and connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- from 0.38 to 1.03 volts. - AT Wide open throttle -- 3.1 to 4.0 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). CIRCUIT OPERATION From the Powertrain Control Module (PCM) circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3210 Throttle Position Sensor: Testing and Inspection Component Testing To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool and follow the appropriate procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for correct pinout. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3211 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3212 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (20 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications Throttle Body: Specifications Throttle Body Mounting Bolts 23 Nm (200 in lb) Throttle Control Shield 5.6 Nm (50 in lb) IAC Motor-To-Throttle Body Bolts 7 Nm (30 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3216 Throttle Body: Testing and Inspection Fig. 31 PCV Vacuum Nipple 1. Turn ignition key off. 2. Disconnect the PCV valve hose from the intake manifold nipple (Fig. 31). Cap the PCV vacuum nipple. Fig. 32 Purge Hose 3. Disconnect purge hose from the nipple on the throttle body (Fig. 32). Fig. 33 Orifice 6457 Attached To Purge Nipple 4. Use a piece of hose to attach Air Metering Orifice 6457 (0.125 in. orifice) or equivalent, to the purge nipple on the throttle body (Fig. 33). 5. Ensure that all accessories are off. 6. Connect the DRB or equivalent scan tool to the data link connector inside the passenger compartment. 7. Run engine in Park or Neutral until the cooling fan has cycled on and off at least once (180°F). 8. Using the DRB or equivalent scan tool, access Minimum Airflow Idle Speed. 9. The following will then occur: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3217 - Idle air control motor will fully close - Idle spark advance will become fixed - PCM will go open loop enriched - DRB or equivalent scan tool displays engine RPM 10. If idle RPM is within the range shown below, throttle body minimum airflow is set correctly. Odometer Reading Idle RPM Below 1,000 Miles 550 - 1,300 RPM Above 1,000 Miles 600 - 1,300 RPM 11. If idle RPM is above specifications, use the DRB or equivalent scan tool to check idle air control motor operation. If idle air control motor is OK, replace throttle body. If idle air flow is below specification, shut off the engine and clean the throttle body as follows: a. Remove the throttle body from engine. WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves, do not let Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash thoroughly after using cleaner. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when is closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 14. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 12. Shut off engine. 13. Remove Air Metering Orifice 6457 or equivalent. Install purge hose. 14. Remove cap from PCV valve. Connect hose to PCV valve. 15. Remove DRB or equivalent scan tool. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Automatic Transmission Throttle Body: Service and Repair Automatic Transmission Fig. 88 Throttle Body Cables Attachment to Throttle Body Fig. 89 Disconnecting Throttle Cable REMOVAL 1. Remove throttle cable cover. 2. Remove throttle body cables using the following procedures. 3. Remove throttle cable from throttle body cam (Fig. 88) and (Fig. 89). 4. Compress the retaining tabs on the cable and slide cable out of bracket (Fig. 89). Fig. 90 Transmission Kickdown Cable Connector 5. Hold throttle lever in the wide open position. - Using finger pressure only remove kickdown cable by PUSHING connector off the lever nail head (Fig. 88) and (Fig. 90). DO NOT try to pull connector off perpendicular to the lever. 6. Compress the retaining tabs on the cable and slide cable out of bracket (Fig. 89). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Automatic Transmission > Page 3220 Fig. 91 Speed Control Cable Connector 7. if equipped with speed control, hold throttle lever in the wide open position. Using finger pressure only -- remove speed control cable by PUSHING connector off the lever nail head (Fig. 88) and (Fig. 91). DO NOT try to pull connector off perpendicular to the lever. 8. Compress the retaining tabs on the cable and slide cable out of bracket (Fig. 89). 9. Remove 2 screws holding cable mounting bracket and support bracket. 10. Remove TPS connection 11. Remove Idle Air Control motor connector. 12. Remove EVAP purge hose. 13. Remove throttle body mounting bolts. Remove throttle body. Fig. 92 Re-Usable Throttle Body Gasket 14. The rubber 0-ring gasket on the intake manifold is reusable. Wipe the 0-ring clean before installing throttle body (Fig. 92). INSTALLATION 1. Install throttle body on intake manifold. Tighten mounting bolts to 23 Nm (200 in lb). 2. Attach cable mounting bracket and support bracket with 2 screws. 3. Connect electrical connection to throttle body. 4. Connect the EVAP purge hose. 5. Install cable housing(s) retainer tabs into bracket. 6. Install throttle body cables using the following procedures. 7. From the engine compartment, rotate the throttle lever forward to the wide open position and install throttle cable clasp (Fig. 89). 8. If equipped with speed control, rotate throttle lever forward to the wide open position and slide speed control cable connector onto nail head. 9. Rotate throttle lever forward to the wide open position and slide kickdown cable connector onto nail head. 10. Install throttle cable cover. Tighten bolt to 5.6 Nm (50 in lb). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Automatic Transmission > Page 3221 Throttle Body: Service and Repair Manual Transmission Fig. 86 Throttle Cable Attachment to Throttle Body Fig. 87 Disconnecting Throttle Cable REMOVAL 1. Remove throttle cable cover. 2. Remove throttle cable from the throttle body cam (Fig. 86) and (Fig. 87). 3. Compress the retaining tabs on the cable and slide cable out of bracket (Fig. 87). 4. If equipped with speed control, remove speed control cable from throttle lever by sliding clasp out hole used for throttle cable. 5. Remove 2 screws holding cable mounting bracket and support bracket. 6. Remove TPS connector. 7. Remove Idle Air Control motor connector. 8. Remove the EVAP purge hose. 9. Remove throttle body mounting bolts. Remove throttle body. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Automatic Transmission > Page 3222 Fig. 92 Re-Usable Throttle Body Gasket 10. The rubber 0-ring gasket on the intake manifold is reusable. - Wipe the 0-ring clean before installing throttle body (Fig. 92). INSTALLATION 1. Install throttle body on intake manifold. Tighten mounting bolts to 23 Nm (200 in lb). 2. Attach cable mounting bracket and support bracket with 2 screws. 3. Connect the electrical connection to the throttle body. 4. Connect the EVAP purge hose to the throttle body 5. Install cable housing(s) retainer tabs into bracket. 6. If equipped with speed control. rotate the throttle lever forward to the wide open position and install speed control cable clasp (Fig. 87). 7. Rotate throttle lever to wide open position and install throttle cable clasp (Fig. 87). 8. Install throttle cable cover. Tighten bolt to 5.6 Nm (50 in lb). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Automatic Transmission Throttle Cable/Linkage: Service and Repair Automatic Transmission Fig. 5 Throttle Body Cables Attachment To Throttle Body Fig. 6 Disconnecting Throttle Cable REMOVAL 1. Working from the engine compartment, remove throttle cable from throttle body cam (Figs. 5 and 6). 2. Compress the retaining tabs on the cable and slide cable out of bracket (Fig. 6). Fig. 2 Accelerator Pedal And Throttle Cable -- Rear View Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Automatic Transmission > Page 3227 Fig. 2 Accelerator Pedal And Throttle Cable -- Rear View 3. From inside the vehicle, hold the throttle pedal up and remove the cable retainer and cable from upper end of pedal shaft (Fig. 1 and Fig. 2). 4. Remove retainer clip from throttle cable and grommet at the dash panel (Fig. 2). 5. From the engine compartment, pull the throttle cable out of the dash panel grommet. The grommet should remain in the dash panel. INSTALLATION 1. From the engine compartment, push the housing end fitting into the dash panel grommet. 2. Install cable housing (throttle body end) into the cable mounting bracket on the engine. 3. From inside the vehicle, hold up pedal and feed throttle cable core wire through hole in upper end of the pedal shaft. Install cable retainer (Fig. 2). 4. Install cable retainer clip (Fig. 2). 5. From the engine compartment, rotate the throttle lever forward to the wide open position and install cable clasp (Fig. 6). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Automatic Transmission > Page 3228 Throttle Cable/Linkage: Service and Repair Manual Transmission Throttle Control Shield REMOVAL 1. Remove throttle control shield. Fig. 3 Throttle Cable Attachment To Throttle Body Fig. 4 Disconnecting Throttle Cable Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Automatic Transmission > Page 3229 2. Working from the engine compartment, remove the throttle cable from the throttle body lever. 3. Compress the retaining tabs on the cable and slide cable out of bracket. Fig. 1 Accelerator Pedal And Throttle Cable -- Front View Fig. 2 Accelerator Pedal And Throttle Cable -- Rear View 4. From inside the vehicle, hold the accelerator pedal up and remove the cable retainer and cable from upper end of pedal shaft. 5. Remove retainer clip from throttle cable and grommet at the dash panel. 6. From the engine compartment, pull the throttle cable out of the dash panel grommet. The grommet should remain in the dash panel. INSTALLATION 1. From the engine compartment, push the housing end fitting into the dash panel grommet. 2. Install cable housing (throttle body end) into the cable mounting bracket on the engine. 3. From inside the vehicle, hold up pedal and feed throttle cable core wire through hole in upper end of the pedal shaft. Install cable retainer. 4. Install cable retainer clip. 5. From the engine compartment, rotate the throttle lever forward to the wide open position and install cable clasp. 6. Install throttle control shield. 7. Tighten screw to 5.6 Nm (50 in lb). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3234 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3235 Throttle Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3236 Throttle Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3237 Throttle Position Sensor: Description and Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS mounts to the throttle body and connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- from 0.38 to 1.03 volts. - AT Wide open throttle -- 3.1 to 4.0 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). CIRCUIT OPERATION From the Powertrain Control Module (PCM) circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3240 Throttle Position Sensor: Testing and Inspection Component Testing To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool and follow the appropriate procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for correct pinout. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3241 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3242 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (20 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Cable Routing and Firing Order Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Cable Routing and Firing Order Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis > Page 3255 Camshaft Position Sensor: Technical Service Bulletins Cam/Crank Sensor - No Start Diagnostics NO: 18-24-97 GROUP: Vehicle Performance DATE: Aug. 8, 1997 SUBJECT: No Start Diagnostics Cam/Crank Sensor $01 and $28 MODELS: 1997 (FJ) Avenger/Sebring/Talon 1997 (GS) Chrysler Voyager (International Market) 1997 (JA) Breeze/Cirrus/Stratus 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1997 (NS) Town & Country/Caravan/Voyager 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L DOHC/SOHC (NATURALLY ASPIRATED), 2.4L, 3.3L, 3.5L, OR 3.8L ENGINE. DISCUSSION: If a vehicle exhibits a no-start due to failure of the cam or crank sensor, the opposite sensor may be reported as the DTC (i.e. bad cam sensor sets crank sensor DTC and vice versa). The faulty sensor may generate a signal strong enough (at key "ON") to be interpreted by the controller as a legitimate signal. Since the engine is not running, the opposite sensor will not be generating any pulses. The controller, expecting corresponding pulses from both sensors, matures a fault for the sensor that is not generating any pulses. In this case, the good sensor is reported as faulty. To verify which sensor is at fault, use the DRB III and select DRB III Standalone, 1994 - 1998 Diagnostics, select Engine system, select Monitor Display, and No Start monitor. Under the No Start monitor the cam and crank sensors should display a no response or LOST on the display. If a sensor is reporting a signal at key ON", it should be replaced. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3258 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3259 Camshaft Position Sensor: Locations Camshaft Position Sensor Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3260 Camshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3261 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity OPERATION The camshaft position sensor attaches to the rear of the cylinder head. A target magnet attaches to the rear of the camshaft and indexes to the Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3262 correct position. The target magnet has four different poles arranged in an asymmetrical pattern (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the camshaft position sensor The K7 circuit connects to cavity 44 of the PCM connector. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 33 of the PCM connector. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing Camshaft Position Sensor: Testing and Inspection Component Testing The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting an oscilloscope and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing > Page 3265 Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing > Page 3266 Camshaft Position Sensor: Testing and Inspection Failure to Start Test Fig.20 Ignition Coil Engine Harness Connector This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Sensor Replacement Camshaft Position Sensor Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head. REMOVAL 1. Remove filtered air tube from the throttle body and air cleaner housing. 2. Disconnect electrical connector from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.35 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft (Fig. 35). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 3269 Fig.36 Target Magnet Installation NOTE: The target magnet has locating dowels that fit into machined locating holes in the end of the camshaft (Fig. 36). INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install filtered air tube. Tighten clamps to 3 Nm ±1 (25 in lb ±5) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 3270 Camshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Cam/Crank Sensor - No Start Diagnostics Crankshaft Position Sensor: Technical Service Bulletins Cam/Crank Sensor - No Start Diagnostics NO: 18-24-97 GROUP: Vehicle Performance DATE: Aug. 8, 1997 SUBJECT: No Start Diagnostics Cam/Crank Sensor $01 and $28 MODELS: 1997 (FJ) Avenger/Sebring/Talon 1997 (GS) Chrysler Voyager (International Market) 1997 (JA) Breeze/Cirrus/Stratus 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1997 (NS) Town & Country/Caravan/Voyager 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L DOHC/SOHC (NATURALLY ASPIRATED), 2.4L, 3.3L, 3.5L, OR 3.8L ENGINE. DISCUSSION: If a vehicle exhibits a no-start due to failure of the cam or crank sensor, the opposite sensor may be reported as the DTC (i.e. bad cam sensor sets crank sensor DTC and vice versa). The faulty sensor may generate a signal strong enough (at key "ON") to be interpreted by the controller as a legitimate signal. Since the engine is not running, the opposite sensor will not be generating any pulses. The controller, expecting corresponding pulses from both sensors, matures a fault for the sensor that is not generating any pulses. In this case, the good sensor is reported as faulty. To verify which sensor is at fault, use the DRB III and select DRB III Standalone, 1994 - 1998 Diagnostics, select Engine system, select Monitor Display, and No Start monitor. Under the No Start monitor the cam and crank sensors should display a no response or LOST on the display. If a sensor is reporting a signal at key ON", it should be replaced. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3277 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position Sensor Bolts ........................................................................................................ .......................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3278 Fig 7 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3279 Crankshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3280 Crankshaft Position Sensor: Description and Operation Fig 7 Crankshaft Position Sensor Fig. 14 Timing Reference Notches Fig.6 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60° signature notch (Fig. 14). The notches generate pulses from high to low in the crankshaft position sensor output voltage. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3281 - When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69° before top dead center (BTDC). - The second notch represents 49° BTDC. - The third notch represents 29°. - The last notch in each set represents 9° before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM connector. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test Fig.20 Ignition Coil Engine Harness Connector This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 3284 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig 7 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Crankshaft Position Sensor Bolts torque ....................................................................................................................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 3287 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum Cables #1 & #4 3,050 Ohms 4,250 Ohms Cables #2 & #3 2,300 Ohms 3,300 Ohms Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 3291 Ignition Cable: Description and Operation NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Plastic clips in various locations protect the cables from damage. When the cables are replaced the clips must be used to prevent damage to the cables. The #1 cable must be routed under the PCV hose and clipped to the #2 cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Ignition Cable: Initial Inspection and Diagnostic Overview Fig. 3 Spark Plug Cables NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Be sure that the plastic clip on PCV hose is positioned so that cable clip is beneath hose, and that #1 cable is snapped into this clip to protect it from metal PCV clamp. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3294 Ignition Cable: Component Tests and General Diagnostics Testing For Open Circuits, High Resistance and Loose Terminals Use an ohmmeter to check cables for opens, loose terminals or high resistance as follows: 1. Remove cable from spark plug. 2. Remove cable from the coil tower. 3. Connect the ohmmeter between the spark plug end terminal and the coil end terminal. - Make sure ohmmeter probes are in good contact. - Resistance should be within tolerance shown in the cable resistance chart. - If resistance is not within tolerance, replace cable assembly. Test all spark plug cables in the same manner. - If no problems are found, SEE Ignition System/System Diagnosis/Testing For Spark At Coil. SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum Cables #1 & #4 3,050 Ohms 4,250 Ohms Cables #2 & #3 2,300 Ohms 3,300 Ohms Testing For Punctures and Cracks When testing cables for punctures and cracks with an oscilloscope and an inductive voltage probe, follow the instructions of the equipment manufacturers. CAUTION: Do not leave any one spark plug cable disconnected for more than 30 seconds during test or possible heat damage to catalytic converter will occur. If an oscilloscope and inductive probe are not available, cables can be tested as follows: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. WARNING: The ignition system generates approximately 40,000 volts. Personal injury could result from contact with this system. 2. With the engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). - If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. - Replace cracked, leaking or faulty cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair > Cleaning Ignition Cable: Service and Repair Cleaning Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair > Cleaning > Page 3297 Ignition Cable: Service and Repair Replacement Fig. 3 Spark Plug Cables NOTE: The cables insulate the spark plugs and cover the top of the spark plug tube (Fig. 3). CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. REMOVAL 1. Remove spark plug cable from coil first. Lightly grasp the top of the cable. 2. Rotate the insulator 1/2 turn and pull straight up in a steady motion. 3. To replace the cables, disconnect the cable from the ignition coil. INSTALLATION Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube.Then connect the other end to coil pack. Be sure that the plastic clip on PCV hose is positioned so that cable clip is beneath hose, and that #1 cable is snapped into this clip to protect it from metal PCV clamp. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications Ignition Coil: Electrical Specifications Coil Resistance Primary @ 21-27°C (70-80°F) ........................................................................................................................................................ 0.45 to 0.65 ohms Secondary @ 21-27°C (70-80°F) .............................................................................................................................................. 7,000 to 15,800 ohms Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications > Page 3302 Ignition Coil: Mechanical Specifications Ignition Coil Mounting Bolts ................................................................................................................. ..................................................... 11 Nm (95 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3303 Fig.30 Electronic Ignition Coil Pack Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions Ignition Coil: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3306 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3307 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3308 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3309 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3310 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3311 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3312 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3313 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3314 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3315 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3316 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3317 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3318 Ignition Coil: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3319 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3320 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3321 Ignition Coil Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3322 Cable Routing and Firing Order Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3323 Ignition Coil: Description and Operation Fig.4 Ignition Coil Pack WARNING: The direct ignition system generates approximately 40,000 volts. Personal injury could result from contact with this system. OPERATION The coil pack consists of 2 coils molded together The coil pack is mounted on the valve cover (Fig. 4). High tension leads route to each cylinder from the coil. The coil fires two spark plugs every power stroke. One plug is the cylinder under compression, the other cylinder fires on the exhaust stroke. Coil number one fires cylinder 1 and 4. Coil number two fires cylinders 2 and 3. The PCM determines which of the coils to charge and fire at the correct time. Fig.5 Power Distribution Center (PDC) The Auto Shutdown (ASD) relay provides battery voltage to the ignition coil. The PCM provides a ground contact (circuit) for energizing the coil. When the PCM breaks the contact, the energy in the coil primary transfers to the secondary causing the spark. The PCM will de-energize the ASD relay if it does not receive the crankshaft position sensor and camshaft position sensor inputs. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3324 Coil Polarity CIRCUIT OPERATION Circuit A14 is a bus bar in the Power Distribution Center (PDC), and connects to battery voltage. The contact side of the Automatic Shut Down ( ASD) relay connects circuit A14 and circuit A142. A 20 Amp fuse in the PDC protects circuits A14 and A142. Circuit A14 also supplies voltage to the coil side of the ASD relay The Powertrain Control Module (PCM) controls the ground path circuit for the coil side of the ASD relay on circuit K51. Circuit K51 connects to cavity 67 of the PCM connector. Circuit A142 supplies voltage for the ignition coil pack. The coil pack consists of two individual coils molded together. The PCM controls the ground circuit of each coil. Circuit K19 is the ground circuit for the ignition coil that fires spark plugs # 1 and # 4. Circuit K19 connects to cavity 2 of the PCM. - Circuit K17 is the ground circuit for the ignition coil that fires spark plugs #2 and # 3. Circuit K17 connects to cavity 3 of the PCM. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Helpful Information Ignition Coil: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, ASD relay, generator, upstream heated oxygen sensor and downstream heated oxygen sensor. The PCM controls the ground circuit for each of the components powered by circuit A142. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Helpful Information > Page 3327 Ignition Coil: Testing and Inspection Ignition Coil Test Fig.18 Terminal Identification NOTE: Coil one fires cylinders 1 and 4, coil two fires cylinders 2 and 3. Each coil tower is labeled with the number of the corresponding cylinder. 1. Remove the ignition cables and measure the resistance of the cables. Resistance must be between ranges shown. Replace any cable not within tolerance. Secondary Ignition Cable Resistance Minimum Maximum Cables #1 & #4 3,050 Ohms 4,250 Ohms Cables #2 & #3 2,300 Ohms 3,300 Ohms 2. Disconnect the electrical connector from the coil pack. 3. Measure the primary resistance of each coil. At the coil, connect an ohmmeter between the B+ pin and the pin corresponding to the cylinders in question (Fig. 18). Resistance on the primary side of each coil should be 0.45 - 0.65 ohm. Replace the coil if resistance is not within tolerance. 4. Remove ignition cables from the secondary towers of the coil. Measure the secondary resistance of the coil between the towers of each individual coil (Fig. 19). Secondary resistance should be 11,000 to 14,000 ohms. Replace the coil if resistance is not within tolerance. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Page 3328 Ignition Coil: Service and Repair Fig.30 Electronic Ignition Coil Pack NOTE: The electronic ignition coil pack attaches to a bracket mounted on top of the cylinder head cover (Fig. 30). REMOVAL 1. Disconnect electrical connector from coil pack. 2. Remove coil pack mounting nuts. 3. Remove coil. 4. Install coil pack on valve cover. 5. Transfer spark plug cables to new coil pack. - The coil pack towers are numbered with the cylinder identification. NOTE: Be sure the ignition cables snap onto the towers. Ignition Coil Mounting Bolts ................................................................................................................. .................................................... 11 Nm (95 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 3332 Knock Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 3333 Knock Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 3334 Knock Sensor: Description and Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 24 of the PCM connector. The PCM provides ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Testing and Inspection > Helpful Information Knock Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3337 Knock Sensor: Testing and Inspection Component Testing The knock sensor can be tested with a digital voltmeter. Sensor output should be between 80 mV and 4 volts with the engine running between 576 and 2,208 rpm. If the output falls outside of this range a DTC will be set. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Testing and Inspection > Page 3338 Knock Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis > Page 3344 Camshaft Position Sensor: Technical Service Bulletins Cam/Crank Sensor - No Start Diagnostics NO: 18-24-97 GROUP: Vehicle Performance DATE: Aug. 8, 1997 SUBJECT: No Start Diagnostics Cam/Crank Sensor $01 and $28 MODELS: 1997 (FJ) Avenger/Sebring/Talon 1997 (GS) Chrysler Voyager (International Market) 1997 (JA) Breeze/Cirrus/Stratus 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1997 (NS) Town & Country/Caravan/Voyager 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L DOHC/SOHC (NATURALLY ASPIRATED), 2.4L, 3.3L, 3.5L, OR 3.8L ENGINE. DISCUSSION: If a vehicle exhibits a no-start due to failure of the cam or crank sensor, the opposite sensor may be reported as the DTC (i.e. bad cam sensor sets crank sensor DTC and vice versa). The faulty sensor may generate a signal strong enough (at key "ON") to be interpreted by the controller as a legitimate signal. Since the engine is not running, the opposite sensor will not be generating any pulses. The controller, expecting corresponding pulses from both sensors, matures a fault for the sensor that is not generating any pulses. In this case, the good sensor is reported as faulty. To verify which sensor is at fault, use the DRB III and select DRB III Standalone, 1994 - 1998 Diagnostics, select Engine system, select Monitor Display, and No Start monitor. Under the No Start monitor the cam and crank sensors should display a no response or LOST on the display. If a sensor is reporting a signal at key ON", it should be replaced. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3347 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3348 Camshaft Position Sensor: Locations Camshaft Position Sensor Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3349 Camshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3350 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity OPERATION The camshaft position sensor attaches to the rear of the cylinder head. A target magnet attaches to the rear of the camshaft and indexes to the Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3351 correct position. The target magnet has four different poles arranged in an asymmetrical pattern (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the camshaft position sensor The K7 circuit connects to cavity 44 of the PCM connector. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 33 of the PCM connector. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing Camshaft Position Sensor: Testing and Inspection Component Testing The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting an oscilloscope and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing > Page 3354 Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Component Testing > Page 3355 Camshaft Position Sensor: Testing and Inspection Failure to Start Test Fig.20 Ignition Coil Engine Harness Connector This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Sensor Replacement Camshaft Position Sensor Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head. REMOVAL 1. Remove filtered air tube from the throttle body and air cleaner housing. 2. Disconnect electrical connector from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.35 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft (Fig. 35). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 3358 Fig.36 Target Magnet Installation NOTE: The target magnet has locating dowels that fit into machined locating holes in the end of the camshaft (Fig. 36). INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install filtered air tube. Tighten clamps to 3 Nm ±1 (25 in lb ±5) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 3359 Camshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Cam/Crank Sensor - No Start Diagnostics Crankshaft Position Sensor: Technical Service Bulletins Cam/Crank Sensor - No Start Diagnostics NO: 18-24-97 GROUP: Vehicle Performance DATE: Aug. 8, 1997 SUBJECT: No Start Diagnostics Cam/Crank Sensor $01 and $28 MODELS: 1997 (FJ) Avenger/Sebring/Talon 1997 (GS) Chrysler Voyager (International Market) 1997 (JA) Breeze/Cirrus/Stratus 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1997 (NS) Town & Country/Caravan/Voyager 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L DOHC/SOHC (NATURALLY ASPIRATED), 2.4L, 3.3L, 3.5L, OR 3.8L ENGINE. DISCUSSION: If a vehicle exhibits a no-start due to failure of the cam or crank sensor, the opposite sensor may be reported as the DTC (i.e. bad cam sensor sets crank sensor DTC and vice versa). The faulty sensor may generate a signal strong enough (at key "ON") to be interpreted by the controller as a legitimate signal. Since the engine is not running, the opposite sensor will not be generating any pulses. The controller, expecting corresponding pulses from both sensors, matures a fault for the sensor that is not generating any pulses. In this case, the good sensor is reported as faulty. To verify which sensor is at fault, use the DRB III and select DRB III Standalone, 1994 - 1998 Diagnostics, select Engine system, select Monitor Display, and No Start monitor. Under the No Start monitor the cam and crank sensors should display a no response or LOST on the display. If a sensor is reporting a signal at key ON", it should be replaced. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3366 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position Sensor Bolts ........................................................................................................ .......................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3367 Fig 7 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3368 Crankshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3369 Crankshaft Position Sensor: Description and Operation Fig 7 Crankshaft Position Sensor Fig. 14 Timing Reference Notches Fig.6 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60° signature notch (Fig. 14). The notches generate pulses from high to low in the crankshaft position sensor output voltage. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3370 - When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). - When a notch aligns with the sensor, voltage goes high (5.0 volts). - As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69° before top dead center (BTDC). - The second notch represents 49° BTDC. - The third notch represents 29°. - The last notch in each set represents 9° before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM connector. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test Fig.20 Ignition Coil Engine Harness Connector This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 3373 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig 7 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Crankshaft Position Sensor Bolts torque ....................................................................................................................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 3376 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation SYSTEM OPERATION Ignition Lock Cylinder Detents The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detents: - Accessory - Off (lock) - Unlock - On/Run - Start Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 3381 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Detentes The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detentes: Accessory - Off (lock) - Unlock - On/Run - Start REMOVAL 1. Disconnect negative cable from battery. 2. Place key cylinder in RUN position. - Through the hole in the lower shroud, depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. - Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. - To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. - Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Connect negative cable to battery Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 3385 Knock Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 3386 Knock Sensor Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 3387 Knock Sensor: Description and Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 24 of the PCM connector. The PCM provides ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Helpful Information Knock Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3390 Knock Sensor: Testing and Inspection Component Testing The knock sensor can be tested with a digital voltmeter. Sensor output should be between 80 mV and 4 volts with the engine running between 576 and 2,208 rpm. If the output falls outside of this range a DTC will be set. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Page 3391 Knock Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... .......................................................... (0.033-0.038 in) Torque ............................................................ ............................................................................................................................................... 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3395 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ....................................................................... RC9YC Thread Size .................................................... ................................................................................................................................................. (14mm) 3/4 in. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3396 Spark Plug: Description and Operation Resistor spark plugs are used in this engine. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for spark plug diagnosis. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3399 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear - Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3400 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3401 Spark Plug: Testing and Inspection Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3402 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear - Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3403 clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Heavy Colored Deposits DESCRIPTION: Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on the side facing the intake valve. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap, and reinstall .............................................................................................................................................................. .................................................................................... Normal Operating Conditions NORMAL OPERATING CONDITIONS Normal Operation And Cold(Carbon) Fouling The few deposits present will be probably light tan or slightly gray in color with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 1600 km (1000 miles) of operation for non Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3404 platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, have the electrodes filed and regapped, and then reinstalled. CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum spark plugs. This would damage the platinum pads which would shorten spark plug life. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit. The rust color deposits can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Oil or Ash Encrusted OIL OR ASH ENCRUSTED Oil Or Ash Encrusted If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of spark plugs. Ash encrusted spark plugs can be cleaned and reused. Premature Electrode Wear - Preignition Damage PREIGNITION DAMAGE Preignition Damage Excessive combustion chamber temperature can cause preignition damage. First, the center electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Other possible causes include ignition timing over-advanced and incorrect spark plug heat range. Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3405 center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Determine if the spark plugs are the correct type, as specified on the VECI label, or if other operating conditions are causing engine overheating. Red, Brown, Yellow or White Deposits - Fuel Additives SCAVENGER DEPOSITS Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed using standard procedures. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and reused. Shiny Yellow Glaze COMBUSTION DEPOSITS A shiny yellow glaze coating on the spark plug insulator is evidence of metallic by-products of fuel combustion, caused by chemical additives in certain fuels. Avoid sudden acceleration with wide open throttle after long periods of low speed driving. Spark plugs with combustion deposits can be cleaned and reused. Spark Plug Inspection - Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance Schedules. - Spark plugs that have low mileage may be cleaned and reused if not otherwise defective -- SEE Spark Plug Condition. After cleaning, file the center electrode flat with a small point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The spark plug gap is 0.033 to0.038 in. - Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Wet Oily Deposits FUEL FOULING A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air and reinstall them in the engine. White or Gray - Burned or Blistered Insulator SPARK PLUG OVERHEATING Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3406 Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in. per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug overheating. Also check for lean air-fuel mixture. Check the torque value of the plugs to ensure good plug-engine seat contact. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 3407 Spark Plug: Adjustments Setting Spark Plug Electrode Gap Fig.2 Setting Spark Plug Electrode Gap Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground -- center electrode. Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap .............................................................................................................................................. ............................................. 0.033 to 0.038 in Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 3408 Spark Plug: Service and Repair CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. CAUTION: Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion. SPARK PLUG REMOVAL 1. Remove the spark plug using a quality socket with a rubber or foam insert. 2. Inspect the spark plug condition. SPARK PLUG CLEANING Spark plugs that have low mileage may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. SPARK PLUG INSTALLATION 1. To avoid cross threading, start the spark plug into the cylinder head by hand. 2. Tighten spark plugs to 28 Nm (20 ft lb) torque. 3. Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube. 4. Connect coil. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations The Torque Converter Clutch Solenoid is located on the Valve Body. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3417 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3418 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3419 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3420 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3421 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3422 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3423 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3424 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3425 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3426 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3427 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3428 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3429 Torque Converter Clutch Solenoid: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3430 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3431 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3432 Connector Pin-Outs (Part 31 Of 32) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3433 Fuel And Ignition Diagrams (Part 8 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3434 Torque Converter Clutch Solenoid: Description and Operation If the solenoid wiring connector is unplugged, the torque converter will not engage. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation CIRCUIT OPERATION The PRNDL lamp receives power on the E2 circuit from the 4 Amp fuse located in the fuse block in cavity 12. The fuse receives power from the headlamp switch. Circuit E2 also powers the ash receiver lamp. When the headlamp switch is moved to the PARK or ON position, current flows through the fuse to the PRNDL lamp. The ground for the lamp is supplied on the Z3 circuit, and terminates at the instrument panel left center support. This circuit is also spliced in with the ash receiver lamp, the ignition switch lamp, and the glove box lamp. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Service and Repair Transmission Mode Indicator - A/T: Service and Repair REMOVAL Floor Console With Transmission Range Indicator 1. Raise the floor console. 2. Remove the attaching screw from each of the two forward cup holders of the floor console. Remove the screws at the rear of the console or inside of the armrest console bin. 3. Pull the parking brake lever all the way up. 4. Lift the floor console at the rear high enough to gain access to the lamp and socket. 5. Remove the indicator lamp socket from bezel to replace the lamp. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Throttle Position Sensor Mounting Screws 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3453 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3454 Transmission Position Switch/Sensor: Description and Operation Fig. 20 Park/Neutral Switch OPERATION On vehicles with 3-speed automatic transmission the park/neutral switch provides an input to the Powertrain Control Module (PCM). The park/neutral position switch is located on the automatic transaxle housing Fig. 20. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. CIRCUIT OPERATION When CLOSED the Transmission Range Switch (TRS) provides an input to the Powertrain Control Module (PCM) on circuit T41. This circuit connects to cavity 76 of the PCM connector. The T41 circuit is spliced and provides a ground path for the engine starter relay, and the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3463 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3464 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3465 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 182896 > Oct > 96 > PCM - Stumble/Rpm Flare/Low Performance With A/C ON PROM - Programmable Read Only Memory: Customer Interest PCM - Stumble/Rpm Flare/Low Performance With A/C ON NO: 18-28-96 GROUP: Vehicle Performance DATE: Oct. 4, 1996 SUBJECT: Cold Start Stumble, RPM Flare (MTX), Performance With A/C On, Radiator Steams MODELS: 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1997 MODELS BUILT PRIOR TO SEPTEMBER 23, 1996 MDH (09-23-XX). SYMPTOM/CONDITION: 1. Engine stumble within 10 seconds of a cold start. If this condition persists after repair, it is recommended to change fuel brands. 2. RPM flares slightly when A/C or power steering loads are released, MTX only. 3. Vehicle lacks performance on low speed tip-in with A/C on, more noticeable on ATX vehicles. Does not improve vehicle launch performance. 4. Radiator "steams" during warm-up. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. Test the Idle Air Control (IAC) by performing the IAC wiggle test. Select Engine System Test IAC wiggle test, follow screen prompts. If the IAC wiggle test fails, repair as necessary before proceeding. If the IAC wiggle test passes and no DTC's are present, perform the Repair Procedure. EQUIPMENT REQUIRED: All Symptoms (Flash Programming) 1 CH6000 Scan Tool(DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 20 OR HIGHER AND TIL CD RELEASE 1117 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes) for all conditions listed. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select #2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 182896 > Oct > 96 > PCM - Stumble/Rpm Flare/Low Performance With A/C ON > Page 3470 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-46-92 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3476 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3477 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3478 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3479 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3480 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3481 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3482 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3483 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3484 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3485 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3486 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3487 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3488 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3489 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3490 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3491 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3492 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3493 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3494 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-47-98 > Dec > 98 > PCM - Symptomless Misfire DTC's/MIL ON PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Symptomless Misfire DTC's/MIL ON NO: 18-47-98 GROUP: Vehicle Performance DATE: Dec. 18, 1998 SUBJECT: Symptom less Misfire Diagnostic Trouble Codes (DTC's) MODELS: 1997 - 1999 (PL) Neon NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 2.0L SOHC/DOHC ENGINE BUILT PRIOR TO NOV. 3, 1998 (MDH 1103XX). SYMPTOM/CONDITION: Some vehicles may exhibit a condition where the MIL illuminates for misfire but no reasons can be found for the misfire fault occurrence. In some cases, there may be minor engine roughness on initial cold engine start-up. Customers may explain the condition as a MIL illumination "only" with no other symptoms felt or noticed. In many cases the occurrence is experienced on a cold engine start. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If non misfire related Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If SINGLE or MULTIPLE CYLINDER MIS-FIRE DTC's are present, follow all mis-fire diagnostics listed in the appropriate Diagnostic Procedures Manual before proceeding with this flash repair. If no cause for the MIS-FIRE DTC's are found, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1175 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 CONNECT TO MDS 1 OR MDS 2 on the DRB III(R) MAIN MENU Screen. 3. Select # 1 MDS DIAGNOSTICS OR DRB UPDATE on the DRB III(R). 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-47-98 > Dec > 98 > PCM - Symptomless Misfire DTC's/MIL ON > Page 3499 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III(R) on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III(R) will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-40-99 PCM, Reprogram 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3504 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3505 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3506 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 182896 > Oct > 96 > PCM - Stumble/Rpm Flare/Low Performance With A/C ON PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Stumble/Rpm Flare/Low Performance With A/C ON NO: 18-28-96 GROUP: Vehicle Performance DATE: Oct. 4, 1996 SUBJECT: Cold Start Stumble, RPM Flare (MTX), Performance With A/C On, Radiator Steams MODELS: 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1997 MODELS BUILT PRIOR TO SEPTEMBER 23, 1996 MDH (09-23-XX). SYMPTOM/CONDITION: 1. Engine stumble within 10 seconds of a cold start. If this condition persists after repair, it is recommended to change fuel brands. 2. RPM flares slightly when A/C or power steering loads are released, MTX only. 3. Vehicle lacks performance on low speed tip-in with A/C on, more noticeable on ATX vehicles. Does not improve vehicle launch performance. 4. Radiator "steams" during warm-up. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. Test the Idle Air Control (IAC) by performing the IAC wiggle test. Select Engine System Test IAC wiggle test, follow screen prompts. If the IAC wiggle test fails, repair as necessary before proceeding. If the IAC wiggle test passes and no DTC's are present, perform the Repair Procedure. EQUIPMENT REQUIRED: All Symptoms (Flash Programming) 1 CH6000 Scan Tool(DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 20 OR HIGHER AND TIL CD RELEASE 1117 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes) for all conditions listed. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select #2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 182896 > Oct > 96 > PCM - Stumble/Rpm Flare/Low Performance With A/C ON > Page 3511 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-46-92 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3517 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3518 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3519 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3520 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3521 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3522 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3523 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3524 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3525 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3526 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3527 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3528 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3529 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3530 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3531 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3532 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3533 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3534 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3535 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-47-98 > Dec > 98 > PCM - Symptomless Misfire DTC's/MIL ON PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Symptomless Misfire DTC's/MIL ON NO: 18-47-98 GROUP: Vehicle Performance DATE: Dec. 18, 1998 SUBJECT: Symptom less Misfire Diagnostic Trouble Codes (DTC's) MODELS: 1997 - 1999 (PL) Neon NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 2.0L SOHC/DOHC ENGINE BUILT PRIOR TO NOV. 3, 1998 (MDH 1103XX). SYMPTOM/CONDITION: Some vehicles may exhibit a condition where the MIL illuminates for misfire but no reasons can be found for the misfire fault occurrence. In some cases, there may be minor engine roughness on initial cold engine start-up. Customers may explain the condition as a MIL illumination "only" with no other symptoms felt or noticed. In many cases the occurrence is experienced on a cold engine start. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If non misfire related Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If SINGLE or MULTIPLE CYLINDER MIS-FIRE DTC's are present, follow all mis-fire diagnostics listed in the appropriate Diagnostic Procedures Manual before proceeding with this flash repair. If no cause for the MIS-FIRE DTC's are found, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1175 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 CONNECT TO MDS 1 OR MDS 2 on the DRB III(R) MAIN MENU Screen. 3. Select # 1 MDS DIAGNOSTICS OR DRB UPDATE on the DRB III(R). 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-47-98 > Dec > 98 > PCM - Symptomless Misfire DTC's/MIL ON > Page 3540 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III(R) on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III(R) will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-40-99 PCM, Reprogram 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations The Torque Converter Clutch Solenoid is located on the Valve Body. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3549 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3550 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3551 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3552 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3553 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3554 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3555 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3556 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3557 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3558 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3559 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3560 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3561 Torque Converter Clutch Solenoid: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3562 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3563 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3564 Connector Pin-Outs (Part 31 Of 32) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3565 Fuel And Ignition Diagrams (Part 8 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3566 Torque Converter Clutch Solenoid: Description and Operation If the solenoid wiring connector is unplugged, the torque converter will not engage. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations The Torque Converter Clutch Solenoid is located on the Valve Body. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3574 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3575 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3576 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3577 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3578 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3579 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3580 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3581 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3582 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3583 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3584 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3585 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3586 Torque Converter Clutch Solenoid: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3587 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3588 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3589 Connector Pin-Outs (Part 31 Of 32) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3590 Fuel And Ignition Diagrams (Part 8 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3591 Torque Converter Clutch Solenoid: Description and Operation If the solenoid wiring connector is unplugged, the torque converter will not engage. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications Band: Specifications ADJUSTMENTS: Kickdown, Backed Off From 8 Nm (72 inch lbs.) ........................................................................................................................................... 2 1/4 Turns Low-Reverse, Backed Off From 5 Nm (41 inch lbs.) ...................................................................................................................................... 3 1/2 Turns TORQUE: Kickdown Band Adjustment Locknut ................................................................................................................................................... 47 Nm (35 ft. lbs.) Reverse Band Adjustment Locknut ................................................................................................................................................. 14 Nm (125 inch lbs.) Reverse Band Shaft Plug ............................................................................................. ........................................................................ 7 Nm (60 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Page 3595 Band: Adjustments KICKDOWN BAND (FRONT) The kickdown band adjusting screw is located on left side (top front) of the transaxle case. 1. Loosen locknut and back-off nut approximately five turns. Test adjusting screw for free turning in the transaxle case. 2. Using wrench, tighten adjusting screw to 8 Nm (72 inch lbs.). 3. Back-off adjusting screw 2 1/4 turns. Hold adjusting screw in this position and tighten locknut to 47 Nm (35 ft. lbs.) LOW/REVERSE BAND (REAR) To adjust low/reverse band, proceed as follows: 1. Loosen and back off locknut approximately five turns. 2. Using an inch-pound torque wrench, tighten adjusting screw to 5 Nm (41 inch lbs.) true torque. 3. Back-off adjusting screw 3 1/2 turns. 4. Tighten locknut to 14 Nm (10 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Bell Housing, A/T > Component Information > Specifications Bell Housing: Specifications Cover Bolts .......................................................................................................................................... ............................................... 12 Nm (105 inch lbs.) Lower Cover Screw .......................................... ........................................................................................................................................ 41 Nm (30 ft. lbs.) To Cylinder Block Bolts ................................................................................................................ ........................................................... 95 Nm (70 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Specifications Case: Specifications Rear Cover To Case Screw ................................................................................................................. ................................................ 19 Nm (165 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications Clutch: Specifications CLEARANCES: Front Clutch (Non-Adjustable)* ................................................................................................................................ 1.27 - 2.79 mm (0.050 - 0.110 inch) Rear Clutch 4 Disc (Adjustable) ............................................................................................................................... 0.71 - 1.10 mm (0.028 - 0.043 inch) SELECTIVE SNAP RINGS: Size 1 ................................................................................................................................................... ...................... 1.22 - 1.27 mm (0.048 - 0.050 inch) Size 2 .................................................................. ....................................................................................................... 1.52 - 1.57 mm (0.060 - 0.062 inch) Size 3 .......................................................................................................................................... ............................... 1.73 - 1.78 mm (0.068 - 0.070 inch) Size 4 ......................................................... ................................................................................................................ 1.88 - 1.93 mm (0.074 0.076 inch) Size 5 ................................................................................................................................ ......................................... 2.21 - 2.26 mm (0.087 - 0.089 inch) * NOTE: Measured From Reaction Plate To "Farthest Wave" On A 4 Disc Setup. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Page 3605 Measuring Rear Clutch Plate Clearance Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Carrier Assembly, A/T > Carrier Bearings, A/T > Component Information > Specifications Carrier Bearings: Specifications Retainer Bolts ...................................................................................................................................... ................................................ 34 Nm (300 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Case, A/T > Component Information > Specifications Differential Case: Specifications Mounting Bolts ..................................................................................................................................... ............................................... 19 Nm (165 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Ring Gear, A/T > Component Information > Specifications Ring Gear: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 95 Nm (70 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications Extension Housing: Specifications To Case Bolts ...................................................................................................................................... ................................................ 28 Nm (250 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3627 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3628 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3629 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3630 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3631 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Service Fill ........................................................................................................................................... ............................................................. 3.7L (4.0 Qt) Overhaul with torque converter empty .............................................................................................................................................................. 8.1L (8.6 Qt) Overhaul with torque converter empty (fleet vehicles) ..................................................................................................................................... 8.7L (9.2 Qt) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 3634 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ............................................................................................................ ....................................................... MOPAR ATF +4 Type 9602 or Equivalent Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Specifications Fluid Filter - A/T: Specifications Mounting Screw ................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications Fluid Line/Hose: Specifications To Radiator .......................................................................................................................................... ............................................... 12 Nm (105 inch lbs.) To Transaxle .................................................... ................................................................................................................................... 28 Nm (250 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Mounting Bolts ..................................................................................................................................... ............................................... 19 Nm (165 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications Fluid Pump: Specifications CLEARANCE: Outer Gear To Pocket ....................................................................................................................................... 0.045 - 0.141 mm (0.0018 - 0.0056 inch) Outer Gear Side Clearance ................................................................................................................................ 0.020 - 0.046 mm (0.0008 - 0.0018 inch) Inner Gear Side Clearance ................................................................................................................................ 0.020 - 0.046 mm (0.0008 - 0.0018 inch) TORQUE: To Case Bolts ...................................................................................................................................... ............................................ 31 Nm (275 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 3647 Fluid Pump: Description and Operation The oil pump used is an internal-external gear type design. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Specifications Governor: Specifications Counterweight Screw .......................................................................................................................... ................................................ 28 Nm (250 inch lbs.) To Support Bolt ............................................... ........................................................................................................................................ 7 Nm (60 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Specifications > Page 3651 Governor: Description and Operation The governor can be serviced by removing the transaxle oil pan and valve body assembly. The governor can be unbolted from the governor support and removed from the transaxle for reconditioning or replacement. When cleaning or assembling the governor, be sure the governor valves move freely in the bores of the governor body. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Input Shaft, A/T > Component Information > Specifications Input Shaft: Specifications End Play .............................................................................................................................................. .......................... 0.19 - 1.50 mm (0.008 - 0.060 inch) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation CIRCUIT OPERATION The PRNDL lamp receives power on the E2 circuit from the 4 Amp fuse located in the fuse block in cavity 12. The fuse receives power from the headlamp switch. Circuit E2 also powers the ash receiver lamp. When the headlamp switch is moved to the PARK or ON position, current flows through the fuse to the PRNDL lamp. The ground for the lamp is supplied on the Z3 circuit, and terminates at the instrument panel left center support. This circuit is also spliced in with the ash receiver lamp, the ignition switch lamp, and the glove box lamp. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Transmission Mode Indicator - A/T > Component Information > Service and Repair Transmission Mode Indicator - A/T: Service and Repair REMOVAL Floor Console With Transmission Range Indicator 1. Raise the floor console. 2. Remove the attaching screw from each of the two forward cup holders of the floor console. Remove the screws at the rear of the console or inside of the armrest console bin. 3. Pull the parking brake lever all the way up. 4. Lift the floor console at the rear high enough to gain access to the lamp and socket. 5. Remove the indicator lamp socket from bezel to replace the lamp. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications Output Shaft: Specifications Gear Strap Bolts .................................................................................................................................. ..................................................... 23 Nm (17 ft. lbs.) Shaft Nut .......................................................... ..................................................................................................................................... 271 Nm (200 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > A/T Pan Gasket - Reusable Design/Installation Technical Service Bulletin # 21-05-99A Date: 990903 A/T Pan Gasket - Reusable Design/Installation NUMBER: 21-05-99 Rev. A GROUP: Transmission DATE: Sep. 03, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-05-99 DATED MARCH 5, 1999 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL PARTS AND MODEL COVERAGE. SUBJECT: Reusable Automatic Transmission Oil Pan Gasket OVERVIEW: This bulletin announces availability and installation of a reusable automatic transmission oil pan gasket. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon **1989** - 1993 (AG) Daytona **1989** - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1989** - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (European Market) 1995 - **2000** (JA) Cirrus/Stratus/Breeze 1996 - **2000** (JX) Sebring Convertible **1993 - 2000 (LH) Concorde/Intrepid/New Yorker/LHS/Vision/300M** 1996 - **2000** (NS) Town & Country/Caravan/Voyager **1995 - 2000 (PL) Neon** **1997 - 2000 (PR) Prowler** DISCUSSION: A reusable silicone gasket has been developed to replace the RTV method of sealing the automatic transmission oil pan. Due to more frequent Automatic Transmission Fluid (ATF) change intervals and the possibility of the fluid foaming if it comes in contact with uncured RTV it is recommended that this gasket be used in all applications. NOTE: THIS GASKET CAN BE REUSED UP TO THREE (3) TIMES. PARTS REQUIRED: **1 05011113AA Gasket, Transmission Oil Pan, 31TH** **1 05011114AA Gasket, Transmission Oil Pan, 42LE** 1 05011115AA Gasket, Transmission Oil Pan, 41TE/AE POLICY: INFORMATION ONLY POLICY: Information Only Installation Procedure 1. With oil pan removed from transmission case for routine service or transmission repair proceed to step # 2. 2. Clean any residue from oil pan and magnet. 3. Replace O-ring and filter on bottom of valve body. 4. Using a plastic or wooden scraper, remove old RTV from transmission case rails. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > A/T Pan Gasket - Reusable Design/Installation > Page 3673 CAUTION: ALUMINUM COMPONENTS ARE VERY SUSCEPTABLE TO METAL TRANSFER WHEN OLD GASKET MATERIAL IS REMOVED FROM THEM. USE EXTREME CARE WHEN CLEANING THESE COMPONENTS. 5. Apply thin coat of transmission fluid to oil pan and transmission case pan rails. 6. Orient reusable gasket properly with bolt holes and assemble oil pan and gasket to transmission case. Tighten oil pan bolts to 19 Nm (165 in lbs.). 7. Refill transmission to the proper level with MOPAR ATF + 3 Type 7176, p/n 05010124AA, or MOPAR ATF +4 Type 9602, p/n 05013457AA, for 1999 JA/LH/PR vehicles. CAUTION: DO NOT OVERFILL TRANSAXLE. DO NOT ADD OIL IF LEVEL IS BETWEEN: LOWER HOLES FOR WARM OIL (100°F). UPPER HOLES FOR HOT OIL (180°F.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Page 3674 Seals and Gaskets: Service and Repair NOTE: The pump oil seal can be replaced without removing the pump and reaction shaft support assembly from the transaxle case. REMOVAL Screw seal remover Tool C-3981-B, or equivalent into seal, then tighten screw portion of tool to withdraw the seal. INSTALLATION To install a new seal, place seal in opening of the pump housing (lip side facing inward). Using Tool C-4193 and Handle Tool C-4171, or equivalents, drive new seal into housing until tool bottoms. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Throttle Position Sensor Mounting Screws 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3679 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3680 Transmission Position Switch/Sensor: Description and Operation Fig. 20 Park/Neutral Switch OPERATION On vehicles with 3-speed automatic transmission the park/neutral switch provides an input to the Powertrain Control Module (PCM). The park/neutral position switch is located on the automatic transaxle housing Fig. 20. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. CIRCUIT OPERATION When CLOSED the Transmission Range Switch (TRS) provides an input to the Powertrain Control Module (PCM) on circuit T41. This circuit connects to cavity 76 of the PCM connector. The T41 circuit is spliced and provides a ground path for the engine starter relay, and the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Service and Repair > Removal Shift Interlock Cable: Service and Repair Removal 1. Disconnect and isolate, the battery negative (-) cable from the vehicle battery. 2. Remove console assembly. 3. Remove the gearshift knob set screw and knob. 4. Remove the screws retaining the gearshift indicator bezel and remove bezel and indicator lamp. 5. Pry up the adjuster lock on the shifter/ignition interlock cable. Unsnap the shifter/ignition interlock cable end fitting from the groove in the gearshift mechanism. 6. Remove the cable core end from the plastic cam of the shifter mechanism. 7. Pull cable up and out of the gearshift mechanism. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Service and Repair > Removal > Page 3686 8. Remove the three screws along the bottom of the lower steering column cover and screw on the left outward face of cover. 9. Grasp the cover and pull rearward until the clips disengage. 10. Remove two screws at the upper area of the column liner and lower left corner. 11. Remove steering column cover and steering column cover liner. 12. Lift up the top cover and cluster bezel until the clips disengage and separate to provide clearance. 13. Insert a screwdriver into access hole in the lower shroud. Depress the cylinder button while rotating the cylinder with the key inserted between the ON and START positions. This will disengage the cylinder from the column. 14. Pull out the key cylinder. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Service and Repair > Removal > Page 3687 15. Remove the three lower-to-upper shroud attaching screws through the bottom of the lower shroud. 16. Separate the upper and 1ower shrouds. 17. Grasp the interlock cable clip and connector. Remove the cable from the interlock housing. 18. Unclip the cable from the retaining clip located within the wiring harness. 19. Remove interlock cable from under center console mounting bracket and out front of dash panel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Service and Repair > Removal > Page 3688 Shift Interlock Cable: Service and Repair Installation CAUTION: When installing interlock cable assembly, care must be taken not to bend exposed cable wire and slug at shifter end of cable. 1. Route interlock cable into lower dash panel. 2. Install the ignition switch into housing. Turn the ignition switch to the RUN position. 3. Install the interlock cable into the interlock housing at the steering column. Verify the cable snaps into the housing. 4. Install interlock cable into routing clip located within the wiring harness. 5. Route interlock cable to the console. 6. Install the cable core end to the plastic cam of the shifter mechanism. Snap the shifter/ignition interlock cable end fitting into the groove in the gearshift mechanism. 7. Adjust the Shifter/Ignition Interlock System. 8. Perform the Shifter/Ignition Interlock System operation check. 9. Install console assembly. 10. Install screws retaining the gearshift indicator bezel and install bezel and indicator lamp. 11. Install the gearshift knob set screw and knob. 12. Install two screws at the upper area of the column liner and lower left corner. 13. Snap the clips in at the lower column cover. Install the three screws along the bottom of the lower steering column cover and screw on the left outward face of cover. 14. Install key cylinder. 15. Position the shrouds in place. Install the three lower-to-upper shroud attaching screws through the bottom of the lower shroud. 16. Reinstall the ignition lock cylinder into housing. 17. Reconnect the battery negative (-) cable to the vehicle battery. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Service and Repair > Removal > Page 3689 Shift Interlock Cable: Service and Repair Adjustment If ignition switch cannot be turned to the LOCK position, with shifter in PARK, an adjustment of the Interlock System may be required. To adjust Shifter/Ignition Interlock System, follow procedure listed below: 1. Disconnect and isolate, the battery negative (-) cable from the vehicle battery. 2. Remove console assembly. 3. Remove the gearshift knob set screw and knob. 4. Remove the screws retaining the gearshift indicator bezel and remove bezel and indicator lamp. 5. Reinstall the gearshift knob. 6. Place shifter in PARK. 7. Turn ignition switch to the LOCK or ACCESSORY position. If cable has lost its adjustment, manually position cable to get key into LOCK or ACCESSORY position. Grasp slug on interlock cable with needle nose pliers and pull back on cable. This will allow the ignition switch to be turned to the LOCK or ACCESSORY position. 8. Check that the interlock cable slug is completely seated into the shifter interlock lever. 9. Check that the ignition switch is still in the LOCK or ACCESSORY position. 10. Pry up the adjuster lock on the shifter/ignition interlock cable. 11. Place a 1 mm (0.040) shim between the larger diameter portion of the shifter gate pin and the plastic cam. 12. The spring on the interlock cable should automatically compensate for the slack in the adjuster. 13. Then snap the interlock adjuster lock onto the cable, and remove the shim. 14. After adjusting the interlock system, perform the Interlock System Operation Check. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation Shifter A/T: Description and Operation The transaxle is controlled by a lever type gearshift incorporated within the console. The control has six selector lever positions: P (Park), R (Reverse), N (Neutral), and D (Drive), 2 (Second), and 1 (First). The parking lock is applied by moving the selector lever past a gate to the (P) position. Do not apply the parking lock until the vehicle has stopped; otherwise, a severe banging noise will occur. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation > Page 3693 Shifter A/T: Service and Repair REMOVAL 1. Remove console assembly. 2. Remove the gearshift knob set screw and knob. 3. Remove the screws retaining the gearshift indicator bezel and remove bezel and indicator lamp. 4. Using a flat-blade pry tool, remove the shifter cable end from the gearshift pin. 5. Pry the two tabs on the cable conduit end away from the gearshift mechanism and pull up on the cable. Remove the gearshift cable from the gearshift mechanism. 6. Pry up the adjuster lock on the shifter/ignition interlock cable. Unsnap the shifter/ignition interlock cable end fitting from the groove in the gearshift mechanism. Remove the cable core end from the plastic cam of the shifter mechanism. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation > Page 3694 7. Remove the nuts at the base of the gearshift mechanism. Remove the shifter mechanism. INSTALLATION For installation, reverse removal steps. Refer to Gearshift Cable Adjustment for proper cable adjustment procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications Shift Cable: Specifications To Case Bolt ........................................................................................................................................ ............................................... 28 Nm (250 inch lbs.) Manual Control Lever Screw .............................................................................................................................................................. 12 Nm (105 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 3699 Shift Cable: Adjustments 1. Set parking brake, then remove floor console. 2. Place gear selector lever in (P) park position, then unsnap collar at shifter cable. 3. Move gear selector lever on transaxle to park position, then verify that both shifter lever and transaxle are in park position. 4. Rotate collar on shift cable adjuster until it seats against plastic housing, Fig.4. Collar must seat against plastic housing to achieve required detent lock position. 5. Inspect adjustment as follows: a. Detent position for neutral and drive should be within limits of hand lever gate stops. b. Key start must occur only when shift lever is in neutral or park positions. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 3700 Shift Cable: Service and Repair REMOVAL 1. Disconnect both battery cables. 2. Pull up and remove the power distribution center. 3. Remove the battery thermo-guard. 4. Remove the battery and battery holddown from the battery tray. 5. Remove the battery tray and cruise control servo (if equipped). 6. Remove the screw from the cable bracket at the transaxle. 7. Squeeze the three metal tabs in and remove the cable from the bracket. 8. Remove the floor console. 9. Remove the gearshift knob set screw and knob. 10. Remove gearshift indicator lamp at shifter bezel. 11. Remove the screws retaining the shifter bezel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 3701 12. Using a flat-blade pry tool, remove the shifter cable core end from the shift lever pin. 13. Using a small screwdriver, pry the cable conduit end tabs away from the shifter mechanism. Pull up on the conduit end and slide the end out of the gearshift mechanism. 14. Remove the three nuts retaining the shift cable grommet plate to the floor pan. 15. Hoist vehicle. 16. Remove the one screw at the shift cable grommet plate. 17. Loosen screws on shift cable grommet plate. Slide plate out and away from heat shield. 18. Carefully remove the cable from the underbody by unfolding the cable retainer clip as you go along. INSTALLATION 1. To install gearshift cable, reverse removal procedure. 2. Adjust gearshift cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Specifications Throttle Valve Cable/Linkage: Specifications To Transaxle Case Bolt ....................................................................................................................... ................................................ 12 Nm (105 inch lbs.) Throttle Lever To Transaxle Shaft Bolt .............................................................................................................................................. 12 Nm (105 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Specifications > Page 3705 Throttle Valve Cable/Linkage: Adjustments The throttle pressure cable adjustment is very important to proper transaxle operation. This adjustment positions a valve which controls shift speed, shift quality, and part throttle downshift sensitivity. If the setting is too long, early shifts and slippage between shifts may occur. If the setting is too short, shifts may be delayed and part throttle downshifts may be very sensitive. 1. Perform transaxle throttle pressure cable adjustment while engine is at normal operating temperature. 2. Release cross-lock on the cable assembly (pull cross-lock upward). 3. To ensure proper adjustment, the cable must be free to slide all the way toward the engine, against its stop, after the cross-lock is released. 4. Move transaxle throttle control lever fully clockwise, against its internal stop, and press cross-lock downward into locked position. The adjustment is complete and transaxle throttle cable backlash was automatically removed. Test cable freedom of operation by moving the transaxle throttle lever forward counterclockwise). Then slowly release it to confirm it will return fully rearward (clockwise). No lubrication is required for any component of the throttle cable system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Specifications > Page 3706 Throttle Valve Cable/Linkage: Service and Repair REMOVAL 1. Unsnap the throttle pressure cable end at the throttle control lever at transaxle. 2. Squeeze the retaining tabs inward at the mounting bracket. Remove the cable from the bracket. 3. Unsnap the cable end from the throttle linkage cam. Squeeze the tabs inward at the bracket. Remove the cable from the vehicle. INSTALLATION To install cable, reverse removal procedure. Then adjust using the following procedure: Adjustment Procedure The throttle pressure cable adjustment is very important to proper transaxle operation. This adjustment positions a valve that controls shift speed, shift quality, and part throttle downshift sensitivity. If the setting is too long, early shifts and slippage between shifts may occur. If the setting is too short, shifts may be delayed and part throttle downshifts may be very sensitive. 1. Perform transaxle throttle pressure cable adjustment while engine is at normal operating temperature. 2. Release cross-lock on the cable assembly (pull cross-lock upward) See illustration. 3. To insure proper adjustment, the cable must be free to slide all the way toward the engine, against its stop, after the cross-lock is released. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Specifications > Page 3707 4. Move transaxle throttle control lever fully clockwise, against its internal stop, and press cross-lock downward into locked position. The adjustment is complete and transaxle throttle cable backlash was automatically removed. Test cable freedom of operation by moving the transaxle throttle lever forward (counterclockwise). Then slowly release it to confirm it will return fully rearward (clockwise). No lubrication is required for any component of the throttle cable system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications Torque Converter: Specifications Outer Diameter .................................................................................................................................... ................................................ 241 mm (9.48 inches) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Description and Operation Torque Converter Clutch: Description and Operation A torque converter clutch is standard on all vehicles. The torque converter clutch is activated only in direct drive and is controlled by the engine electronics. A solenoid on the valve body, is powered by the powertrain control module to activate the torque converter clutch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations The Torque Converter Clutch Solenoid is located on the Valve Body. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3719 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3720 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3721 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3722 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3723 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3724 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3725 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3726 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3727 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3728 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3729 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3730 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3731 Torque Converter Clutch Solenoid: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3732 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3733 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3734 Connector Pin-Outs (Part 31 Of 32) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3735 Fuel And Ignition Diagrams (Part 8 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3736 Torque Converter Clutch Solenoid: Description and Operation If the solenoid wiring connector is unplugged, the torque converter will not engage. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications Transmission Cooler: Specifications Hose Clamps ....................................................................................................................................... .................................................... 2 Nm (18 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 3740 Transmission Cooler: Description and Operation Oil coolers are internal oil to coolant type, mounted in the radiator lower tank. Rubber oil lines feed the oil cooler and the automatic transmission. Use only approved transmission oil cooler hose. Tighten Oil Cooler Hose Clamps to 2 Nm (18 inch lbs.). NOTE: Since these are molded to fit space available, molded hoses are recommended. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 3741 Transmission Cooler: Service and Repair FLUSHING COOLERS AND TUBES When a transaxle failure has contaminated the fluid, the oil cooler (s) must be flushed. The cooler bypass valve in the transaxle must be replaced also. The torque converter must also be replaced with an exchange unit. This will insure that metal particles or sludged oil are not later transferred back into the reconditioned (or replaced) transaxle. There are two different procedures for flushing coolers and lines. The recommended procedure is to use Tool 6906 Cooler Flusher, or equivalent. The other procedure is to use a hand suction gun and mineral spirits. WARNING: Wear protective eye-wear that meets the requirements of OSHA and ANSI Z87.1-1968. wear standard industrial rubber gloves. - Keep lighted cigarettes, sparks, flames, and other ignition sources away from the area to prevent the ignition of combustible liquids and gases. Keep a class (B) fire extinguisher in the area where the flusher will be used. - Keep the area well ventilated. - Do not let flushing solvent come in contact with your eyes or skin: if eye contamination occurs, flush eyes with water for 15 to 20 seconds. Remove contaminated clothing and wash affected skin with soap and water. Seek medical attention. Cooler Flush Using Tool 6906, or Equivalent 1. Remove cover plate filler plug on Tool 6906, or equivalent. Fill reservoir 1/2 to 3/4 full of fresh flushing solution. Flushing solvents are petroleum based solutions generally used to clean automatic transmission components. DO NOT use solvents containing acids, water, gasoline, or any other corrosive liquids. 2. Reinstall filler plug on Tool 6906, or equivalent. 3. Verify pump power switch is turned OFF. Connect red alligator clip to positive (+) battery post. Connect black (-) alligator clip to a good ground. 4. Disconnect the cooler lines at the transmission. NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush. 5. Connect the BLUE pressure line to the OUTLET (From) cooler line. 6. Connect the CLEAR return line to the INLET (To) cooler line 7. Turn pump ON for two to three minutes to flush cooler(s) and lines. Monitor pressure readings and clear return lines. Pressure readings should stabilize below 20 psi. for vehicles equipped with a single cooler and 30 psi. for vehicles equipped with dual coolers. If flow is intermittent or exceeds these pressures, replace cooler. 8. Turn pump OFF. 9. Disconnect CLEAR suction line from reservoir at cover plate. Disconnect CLEAR return line at cover plate, and place it in a drain pan. 10. Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump OFF. 11. Place CLEAR suction line into a one quart container of MOPAR type 9602 automatic transmission fluid, or equivalent. 12. Turn pump ON until all transmission fluid is removed from the one quart container and lines. This purges any residual cleaning solvent from the transmission cooler and lines. Turn pump OFF. 13. Disconnect alligator clips from battery. Reconnect flusher lines to cover plate, and remove flushing adapters from cooler lines. Cooler Flush Using Suction Gun And Mineral Spirits 1. Disconnect the cooler lines at the transmission. 2. Using a hand suction gun filled with mineral spirits, reverse flush the cooler. Force mineral spirits into the From Cooler line of the cooler and catch the exiting spirits from the To Cooler line. Observe for the presence of debris in the exiting fluid. Continue until fluid exiting is clear and Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 3742 free from debris. 3. Using compressed air (under 40 psi) in intermittens spurts, blow any remaining mineral spirits from the cooler, again in the reverse direction. 4. Pump one (1) quart of automatic transmission fluid through the cooler before reconnecting. 5. If at any stage of the cleaning process, the cooler does not freely pass fluid, the cooler must be replaced. OIL COOLER FLOW CHECK After the new or repaired transmission has been installed and filled, the oil cooler flow should be checked using the following procedure: 1. Disconnect the From Cooler line at the transmission and place a collecting container under the disconnected line. 2. Run the engine at curb idle speed, with the shift selector in NEUTRAL. 3. If the fluid flow is intermittent or takes more than 20 seconds to collect one quart, the cooler should be replaced. CAUTION: With the fluid set at the proper level, fluid collection should not exceed (1) quart, or internal damage to the transmission may occur. 4. If flow is found to be within acceptable limits, reconnect the cooler line. Then fill transaxle to the proper level, using the approved type of automatic transmission fluid. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Service and Repair Transmission Mode Indicator - A/T: Service and Repair REMOVAL Floor Console With Transmission Range Indicator 1. Raise the floor console. 2. Remove the attaching screw from each of the two forward cup holders of the floor console. Remove the screws at the rear of the console or inside of the armrest console bin. 3. Pull the parking brake lever all the way up. 4. Lift the floor console at the rear high enough to gain access to the lamp and socket. 5. Remove the indicator lamp socket from bezel to replace the lamp. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Throttle Position Sensor Mounting Screws 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3749 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3750 Transmission Position Switch/Sensor: Description and Operation Fig. 20 Park/Neutral Switch OPERATION On vehicles with 3-speed automatic transmission the park/neutral switch provides an input to the Powertrain Control Module (PCM). The park/neutral position switch is located on the automatic transaxle housing Fig. 20. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. CIRCUIT OPERATION When CLOSED the Transmission Range Switch (TRS) provides an input to the Powertrain Control Module (PCM) on circuit T41. This circuit connects to cavity 76 of the PCM connector. The T41 circuit is spliced and provides a ground path for the engine starter relay, and the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations 31TH Transmission Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications Valve Body: Specifications To Case Bolts ...................................................................................................................................... ................................................ 12 Nm (105 inch lbs.) Valve Body Screw ........................................... ........................................................................................................................................ 5 Nm (45 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 3757 Valve Body: Diagrams Steel Ball Locations Pressure Regulators And Manual Controls Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 3758 Governor Controls Pressure Regulator Valve Plugs Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 3759 Shift Valves And Shuttle Valve Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly Valve Body: Service and Repair Disassembly and Assembly Detent Spring Attaching Screw And Spring Using Tool L-4553 On Valve Body Screw Remove Or Install Valve Body Screws Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3762 Transfer Plate And Separator Plate Steel Ball Locations Remove Or Install Throttle Shaft E-Clip Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3763 Throttle Shaft E-Clip, Washer, And Seal Manual Valve Lever Assembly Throttle Valve Lever Assembly Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3764 Manual Valve Pressure Regulator And Adjusting Screw Bracket Pressure Regulators And Manual Controls Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3765 Governor Controls Pressure Regulator Valve Plugs Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3766 Shift Valves And Shuttle Valve NOTE: Tighten all valve body screws to 5 Nm (40 inch lbs.). Do not clamp any portion of valve body or transfer plate in a vise. Any slight distortion of the aluminum body or transfer plate will result in sticking valves, excessive leakage, or both. When removing or installing valves or plugs, slide them in or out carefully. Do not use force. NOTE: Tag all springs as they are removed for reassembly identification. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3767 Valve Body: Service and Repair Cleaning and Inspection Allow all parts to soak a few minutes in a suitable clean solvent. Wash thoroughly and blow dry with compressed air. Be sure all passages are clean and free from obstructions. Inspect manual and throttle valve operating levers and shafts for being bent, worn or loose. If a lever is loose on its shaft, it should be replaced. Do not attempt to straighten bent levers. Inspect all mating surfaces for burrs, nicks and scratches. Minor blemishes may be removed with crocus cloth. using only a very light pressure. Using a straightedge. inspect all mating surfaces for warpage or distortion. Slight distortion may be corrected, using a surface plate. Be sure all metering holes in steel plate are open. Using a penlight, inspect bores in valve body for scores, scratches, pits, and irregularities. Inspect all valve springs for distortion and collapsed coils. Inspect all valves and plugs for burrs, nicks, and scores. Small nicks and scores may be removed with crocus cloth, providing extreme care is taken not to round off sharp edges. The sharpness of these edges is vitally important. It prevents foreign matter from lodging between valve and valve body. This reduces the possibility of sticking. Inspect all valves and plugs for freedom of operation in valve body bores. When bores, valves, and plugs are clean and dry, the valves and plugs should fall freely in the bores. The valve body bores do not change their dimensions with use. Therefore, a valve body that was functioning properly when vehicle was new, will operate correctly if it is properly and thoroughly cleaned. There is no need to replace a valve body unless it is damaged in handling. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3768 Valve Body: Service and Repair 31TH 3-Speed Cleaning and Inspection CLEANING AND INSPECTION 1. Allow all parts to soak a few minutes in a suitable clean solvent. Wash thoroughly and blow dry with compressed air. Make sure all passages are clean and free from obstructions. 2. Inspect manual and throttle valve operating levers and shafts for being bent, worn or loose. If a lever is loose on its shaft, it should be replaced. Do not attempt to straighten bent levers. 3. Inspect all mating surfaces for burrs, nicks and scratches. Minor blemishes may be removed with crocus cloth, using only a very light pressure. Using a straightedge, inspect all mating surfaces for warpage or distortion. Slight distortion may be corrected, using a surface plate. Make sure all metering holes in steel plate are open. Using a pen light, inspect bores in valve body for scores scratches, pits and irregularities. 4. Inspect all valve springs for distortion and collapsed coils. Inspect all valves and plugs for burrs, nicks, and scores. Small nicks and scores may be removed with crocus cloth, providing extreme care is taken not to round off sharp edges. The sharpness of these edges is vitally important because it prevents foreign matter from lodging between valve and valve body, thus reducing possibility of sticking. Inspect all valves and plugs for freedom of operation in valve body bores. 5. When bores, valves, and plugs are clean and dry, the valves and plugs should fall freely in the bores. The valve body bores do not change dimensionally with use. Therefore, a valve body that was functioning properly when vehicle was new, will operate correctly if it is properly and thoroughly cleaned. There is no need to replace valve body unless it is damaged in handling. 6. Installation is the reverse of removal. Tighten all valve body screws to 5 Nm (40 in.lbs.). Fill transaxle to the proper level with ATF. Overhaul VALVE BODY RECONDITION NOTE: Prior to removing any transaxle subassemblies, plug all openings and thoroughly clean exterior of the unit, preferably by steam. Cleanliness through entire disassembly and assembly cannot be overemphasized. When disassembling, each part should be washed in a suitable solvent, then dried by compressed air. Do not wipe parts with shop towels. All mating surfaces in the transaxles are accurately machined; therefore, careful handling of all parts must be exercised to avoid nicks or burrs. Remove all old R.T.V. sealant before applying new R.T.V. sealant. Use only R.T.V. sealant when installing oil pan. Oil Pan Bolts Oil Pan Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3769 1. Remove or install neutral starting and back-up lamp switch. Oil Filter Screws Oil Filter Parking Rod E-Clip Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3770 Parking Rod Valve Body Attaching Bolts Valve Body And Governor Tubes CAUTION: Do not clamp any portion of valve body or transfer plate in a vise. Any slight distortion of the aluminum body or transfer plate will result in sticking valves, excessive leakage, or both. When removing or installing valves or plugs, slide them in or out carefully. Do not use force. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3771 Detent Spring Attaching Screw And Spring WARNING: Tag all springs as they are removed for reassembly identification. Valve Body Screws Valve Body Screws Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3772 Transfer Plate And Separator Plate Steel Ball Locations Throttle Shaft E-Clip Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3773 E-Clip, Washer And Oil Seal Manual Valve Lever And Assembly Throttle Valve Lever And Assembly Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3774 Manual Valve Pressure Regulator And Adjusting Screw Bracket Pressure Regulators And Manual Controls Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3775 Governor Plugs Pressure Regulator Valve Plugs Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3776 Shift And Shuttle Valve Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Cable > Component Information > Description and Operation Clutch Cable: Description and Operation GENERAL INFORMATION The clutch cable has a unique self-adjuster mechanism built into the cable which compensates for clutch disc wear. The cable requires no maintenance or lubrication. There are no serviceable components on the cable assembly. DESCRIPTION The manual transaxle clutch release system has a unique self-adjusting mechanism to compensate for clutch disc wear. This adjuster mechanism is located within the clutch cable assembly. The preload spring maintains tension on the cable. This tension keeps the clutch release bearing continuously loaded against the fingers of the clutch cover assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Cable > Component Information > Description and Operation > Page 3781 Clutch Cable: Adjustments NOTE: The manual transaxle clutch release system has a unique self-adjusting mechanism to compensate for clutch disc wear. This adjuster mechanism is located within the clutch cable assembly. The preload spring maintains tension on the cable. This tension keeps the clutch release bearing continuously loaded against the fingers of the clutch cover assembly. ADJUSTER MECHANISM FUNCTION CHECK 1. With slight pressure, pull the clutch release lever end of the cable to draw the cable taut. Push the clutch cable housing toward the dash panel. With less than 25 lbs. of effort the cable housing should move 30 - 50 mm. This indicates proper adjuster mechanism function. If the cable does not adjust, determine if the mechanism is properly seated on the bracket. 2. If the adjust mechanism functions properly, guide the cable through the slot in the transaxle housing. Connect cable to release lever, seating the cupped washer securely on lever tangs. 3. Pull back on clutch cable housing and insert into transaxle housing. 4. Reinstall cable inspection cover and air cleaner assembly. Check clutch pedal position switch operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Cable > Component Information > Description and Operation > Page 3782 Clutch Cable: Service and Repair CLUTCH CABLE The manual transaxle clutch release system has a unique self-adjusting mechanism to compensate for clutch disc wear. This adjuster mechanism is located within the clutch cable assembly. The preload spring maintains tension on the cable. This tension keeps the clutch release bearing continuously loaded against the fingers of the clutch cover assembly. REMOVAL 1. Pull up and remove Power Distribution Center. 2. Remove transaxle splash cover. 3. Pun back on clutch cable housing and disengage cable from housing. 4. Guide cable through slot in transaxle and disconnect cable from release lever. 5. Disconnect clutch cable from clutch pedal up- stop/spacer Note: Depressing the clutch pedal provides access to the clutch cable strand. Disconnect the cable end from the spacer by inserting a hooked tool into the clearance hole on the inboard side of the up-upstop/spacer. Now push the cable out- ward. Remove the upstop/spacer by inserting a screwdriver between the spacer and the shoulder of the pin on the clutch pedal. CAUTION: Do not pull on the clutch cable housing to move It from the dash panel. Damage to the cable if adjuster may occur. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Cable > Component Information > Description and Operation > Page 3783 6. Cable End Removal:Use a slight twisting motion while grasping the grommet and body to remove the cable from the dash panel and clutch bracket. a screwdriver may be required to dislodge the cable grommet from the dash panel. Use caution to avoid damage to the cable grommet. INSTALLATION: 1. Using a slight twisting motion, insert the self adjuster mechanism end of the clutch cable through the dash panel hole and into the bracket 2. Seat the 8mm wide groove on the cable grommet in the dash panel. Make sure the self adjuster is firmly seated against the clutch bracket to ensure proper adjuster mechanism function. 3. Connect the clutch cable to the up-step/spacer. 4. Connect the up-stop/spacer to the clutch pedal. 5. Adjuster mechanism function check: With slight pressure, pull the clutch release lever end of the cable to draw the cable taut. Push the clutch cable housing toward the dash panel (With less than 15 lbs. of effort the cable housing should move 30-50mm). This indicates proper adjuster mechanism function. If the cable does not adjust, determine if the mechanism is properly seated on the bracket. 6. If the adjust mechanism functions properly, guide the cable through the slot in the transaxle housing. Connect cable to release lever, seating the cupped washer securely on lever tangs. 7. Pull back on clutch cable housing and insert into transaxle housing. 8. Reinstall splash cover and Power Distribution Center. Check clutch pedal position switch operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Description and Operation Clutch Disc: Description and Operation The clutch disc has cushion springs riveted to the disc hub assembly. The clutch disc facings are riveted to the cushion springs. The facings are made from a non-asbestos material. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications Clutch Fluid Type ..................................................................................................................................................... ................................................ DOT3 Brake Fluid Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications Clutch Pedal Assembly: Specifications Pivot Shaft Nut ..................................................................................................................................... .................................................... 41 Nm (30 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications > Page 3794 Clutch Pedal Assembly: Description and Operation The clutch pedal is connected to the cable through a plastic spacer. The upper end of the clutch pedal pivots in the pedal bracket on two nylon bushings and a shaft. These bushings do not require periodic lubrication. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation The clutch pedal position switch functions as a safety interlock device. It prevents possible engine cranking with the clutch engaged. The clutch pedal position switch is wired in series between the starter relay coil and the ignition switch. The clutch pedal position switch is mounted to a bracket located behind the clutch pedal. The switch is held in place by four plastic wing tabs. The clutch pedal position switch IS NOT adjustable. The pedal blade contacts the switch in the down position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Description and Operation > Page 3798 Clutch Switch: Testing and Inspection ELECTRICAL TEST Disconnect clutch pedal position switch harness from instrument panel wiring harness. Using an ohmmeter, check for continuity between the two terminals in the connector on the switch harness. There should be no continuity between the terminals when the switch is in its normal (fully extended) position. When the switch is depressed more than 1.25 mm (0.050 inch), the ohmmeter should show continuity (zero ohms). If ohmmeter readings do not fall within these ranges, the switch is defective, and must be replaced. MECHANICAL TEST With the park brake set and the vehicle IN NEUTRAL, turn the key to the start position. The vehicle should not crank. If the vehicle cranks, the switch is defective (shorted out) and must be replaced. If the vehicle does not crank proceed to the next step. WARNING: Before performing this step, be sure that the area in front of the vehicle is clear of obstructions and people. Vehicle may move when performing this test. With the park brake set and the vehicle IN GEAR, turn the key to the start position and hold it there. Slowly depress the clutch pedal and feel for any vehicle motion when the starter is energized. If there is no motion the switch is working properly. If motion is felt, check to see if the switch is making contact when the pedal is between 25 mm (1.0 inch) and 6 mm (0.25 inch) from the floor. If this condition is met, then the problem is either the clutch or the self-adjusting cable. If this condition is not met, then the switch mounting tab on the brake bracket is bent, and the brake bracket must be replaced. If vehicle will not crank, even with clutch pedal pressed to the floor, refer to illustrated chart. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Description and Operation > Page 3799 Clutch Switch: Adjustments The clutch pedal position switch is mounted to a bracket located behind the clutch pedal. The switch is held in place by four plastic wing tabs. The clutch pedal position switch IS NOT adjustable. The pedal blade contacts the switch in the down position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Description and Operation > Page 3800 Clutch Switch: Service and Repair NOTES: ^ The clutch pedal position switch is mounted to a bracket located behind the clutch pedal. The switch is held in place by four plastic wing tabs. ^ The clutch pedal position switch IS NOT adjustable. The pedal blade contacts the switch in the down position. REMOVAL 1. Disconnect electrical harness to switch connector. 2. Depress wing tabs on switch and push switch out of mounting bracket. Then slide wires through slot in bracket. INSTALLATION 1. Slide switch wires through slot in switch bracket. 2. Line up switch tab with slot in switch bracket and push switch into position. Do not pull on the switch wires to seat switch into bracket, switch damage may occur. 3. Attach switch wiring harness to vehicle wiring harness. 4. After installation, the switch must be checked for proper operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Description and Operation Clutch Release Bearing: Description and Operation A sleeve-type release bearing is used to engage and disengage the clutch cover pressure plate. The bearing is prelubed during manufacture and is a sealed unit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Description and Operation > Page 3804 Clutch Release Bearing: Service and Repair NOTE: Remove the transaxle from the vehicle. REMOVAL 1. Move the lever and bearing assembly to a vertical in-line position. Grasp the release lever with two hands in the pivot stud socket area. Pull with even pressure and the lever will pop off the pivot-stud. Do not use a screwdriver or pry bar to pop off the lever. This may damage the spring clip on the lever. 2. As a unit, remove the fork from the bearing thrust plate. Be careful not to damage retention tabs on bearing. 3. Examine the condition of the bearing. It is pre-lubricated and sealed and should not be immersed in oil or solvent. 4. The bearing should turn smoothly when held in the hand under a light thrust load. A light drag caused by the lubricant fill is normal. If the bearing is noisy, rough, or dry, replace the complete bearing assembly with a new bearing. 5. Check the condition of the pivot stud spring clips on back side of clutch fork. If the clips are broken or distorted, replace the clutch fork. INSTALLATION 1. The pivot ball pocket in the fork is Teflon coated and should be installed WITHOUT any lubricant such as grease. Using grease will break down the Teflon coating. Be sure the ball stud and fork pocket are clean of contamination and dirt. 2. Assemble the fork to the bearing. The small pegs on the bearing must go over the fork arms. 3. Slide the bearing and fork assembly onto the input shaft bearing retainer, as a unit. 4. Snap the clutch fork onto the pivot ball. 5. Reinstall transaxle assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Description and Operation Clutch Release Fork: Description and Operation The release bearing is operated by a pivoting release fork in the clutch housing. The fork pivots on a ball stud within the housing. The release fork is actuated by a self-adjusting clutch cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Description and Operation > Page 3808 Clutch Release Fork: Service and Repair NOTE: Remove the transaxle from the vehicle. REMOVAL 1. Move the lever and bearing assembly to a vertical in-line position. Grasp the release lever with two hands in the pivot stud socket area. Pull with even pressure and the lever will pop off the pivot-stud. Do not use a screwdriver or pry bar to pop off the lever. This may damage the spring clip on the lever. 2. As a unit, remove the fork from the bearing thrust plate. Be careful not to damage retention tabs on bearing. 3. Examine the condition of the bearing. It is pre-lubricated and sealed and should not be immersed in oil or solvent. 4. The bearing should turn smoothly when held in the hand under a light thrust load. A light drag caused by the lubricant fill is normal. If the bearing is noisy, rough, or dry, replace the complete bearing assembly with a new bearing. 5. Check the condition of the pivot stud spring clips on back side of clutch fork. If the clips are broken or distorted, replace the clutch fork. INSTALLATION 1. The pivot ball pocket in the fork is Teflon coated and should be installed WITHOUT any lubricant such as grease. Using grease will break down the Teflon coating. Be sure the ball stud and fork pocket are clean of contamination and dirt. 2. Assemble the fork to the bearing. The small pegs on the bearing must go over the fork arms. 3. Slide the bearing and fork assembly onto the input shaft bearing retainer, as a unit. 4. Snap the clutch fork onto the pivot ball. 5. Reinstall transaxle assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications MODULAR CLUTCH Drive Plate To Clutch Bolts .................................................................................................................. ................................................ 75 Nm (55 ft. lbs.) CONVENTIONAL CLUTCH To Flywheel Bolts ................................................................................................................................ ........................................... 28 Nm (250 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 3812 Pressure Plate: Description and Operation The clutch cover pressure plate assembly is a diaphragm type unit with a one-piece diaphragm spring with multiple release fingers. The pressure plate release fingers are preset during manufacture and are not adjustable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications Axle Shaft: Specifications Bracket To Transmission ..................................................................................................................... ..................................................... 54 Nm (40 ft. lbs.) To Frame Bracket ............................................ ......................................................................................................................................... 54 Nm (40 ft. lbs.) To Transmission Bracket ......................................................................................................... ................................................................. 54 Nm (40 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 3818 Driveshaft Assembly Components (Exploded View) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 3819 Axle Shaft: Application and ID Driveshafts and driveshaft inner and outer boots can be identified as shown. Driveshaft boot location on the driveshaft assemblies is determined by the number of convolutions on the driveshaft boot. Refer to illustration for the correct location of the sealing boots. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 3820 Axle Shaft: Description and Operation Vehicles equipped with either an automatic or manual transmission use the unequal-length driveshaft system. Vehicles equipped with automatic transaxles use a solid short interconnecting shaft on the left side. The right side of the vehicle uses a longer solid interconnecting shaft. Vehicles equipped with manual transaxles use a larger diameter (32 mm) short interconnecting shaft on the left side. The right side uses a longer interconnecting damper. Driveshafts used on both the right and left sides of the vehicle use a tuned rubber damper weight. The damper weight applications vary by which side of the vehicle the driveshaft is located on and the transmission application of the vehicle. When replacing a driveshaft, be sure the replacement driveshaft has the same damper weight as the original. Both driveshaft assemblies use the same type of inner and outer joints. The inner joint of both driveshaft assemblies is a tripod joint, and the outer joint of both driveshaft assemblies is a Rzeppa joint. Both tripod joints and Rzeppa joints are true constant velocity (C/V) joint assemblies. The inner tripod joint allows for the changes in driveshaft length through the jounce and rebound travel of the front suspension. On vehicles equipped with ABS brakes, the outer C/V joint is equipped with a tone wheel used to determine vehicle speed for ABS brake operation. The inner tripod joint of both driveshafts is splined into the transaxle side gears. The inner tripod joints are retained in the side gears of the transaxle using a snap ring located in the stub shaft of the tripod joint. The outer C/V joint has a stub shaft that is splined into the wheel hub and retained by a hub nut using a nut lock and cotter pin. NOTE: This vehicle does not use a rubber-lip bearing seal as on previous front-wheel-drive cars to prevent contamination of the front wheel bearing. On these vehicles, the face of the outer C/V joint fits deeply into the steering knuckle, using a close outer C/V joint-to-steering knuckle fit. This design deters direct water splash on bearing seal while allowing any water that gets in, to run out the bottom of the steering knuckle bearing bore. it is important to thoroughly clean the outer C/V joint and the wheel bearing area in the steering knuckle before it is assembled after servicing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 3821 Axle Shaft: Testing and Inspection LEAKAGE INSPECTION 1. Check for grease in the vicinity of the inboard tripod joint and outboard C/V joint; this is a sign of inner or outer joint seal boot or seal boot clamp damage. 2. A light film of grease may appear on the right inner tripod joint seal boot; this is considered normal and should not require replacement of the seal boot. NOISE AND/OR VIBRATION IN TURNS A clicking noise and/or a vibration in turns could be caused by one of the following conditions: 1. Damaged outer C/V or inner tripod joint seal boot or seal boot clamps. This will result in the loss and/or contamination of the joint grease, resulting in inadequate lubrication of the joint. 2. Noise may also be caused by another component of the vehicle coming in contact with the driveshafts. CLUNKING NOISE DURING ACCELERATION This noise may be a result of one of the following conditions: 1. A torn seal boot on the inner or outer joint of the driveshaft assembly. 2. A loose or missing clamp on the inner or outer joint of the driveshaft assembly. 3. A damaged or worn driveshaft C/V joint. SHUDDER OR VIBRATION DURING ACCELERATION This problem could be a result of: 1. A worn or damaged driveshaft inner tripod joint. 2. A sticking tripod joint spider assembly (inner tripod joint only). 3. Improper wheel alignment. Refer to Steering and Suspension for alignment checking and setting procedures and specifications. VIBRATION AT HIGHWAY SPEEDS This problem could be a result of: 1. Foreign material (mud, etc.) packed on the backside of the wheel(s). 2. Out of balance front tires or wheels. 3. Improper tire and/or wheel runout. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal Axle Shaft: Service and Repair Removal The content of this article reflects the changes called out by TSB 26-01-95. REMOVAL CAUTION: - Boot sealing is vital to retain special lubricants and to prevent foreign contaminants from entering the C/V joint. Mishandling, such as allowing the assemblies to dangle unsupported, or pulling or pushing the ends can cut boots or damage C/V joints. During removal and installation procedures, always support both ends of the driveshaft to prevent damage. - The driveshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved on its wheels with a driveshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 183 Nm (135 ft. lbs.). This will ensure that the hub bearing cannot loosen. 1. Remove cotter pin, nut lock, and spring washer from the end of the outer C/V joint stub axle. 2. Loosen (but do not remove) stub axle-to-hub/bearing retaining nut. Loosen hub nut while vehicle is on the floor with the brakes applied. The front hub and driveshaft are splined together and retained by the hub nut. 3. Raise vehicle on jack stands or centered on a frame contact-type hoist. 4. Remove front tire and wheel assembly from the hub. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 3824 5. Remove front disc brake caliper assembly to steering knuckle bolts. 6. Remove disc brake caliper assembly from steering knuckle. Caliper is removed by first lifting bottom of caliper away from steering knuckle, and then removing top of caliper out from under steering knuckle. 7. Support brake caliper/adapter assembly using a wire hook, not by the brake flex hose. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 3825 8. Remove braking disc from front hub. 9. Remove nut attaching outer tie rod end to steering knuckle. Nut is to be removed from tie rod end using the following procedure: Hold tie rod end stud with a 11/32 socket while loosening and removing nut. 10. Remove the tie rod end stud from steering knuckle arm using Special Tool MB-990630, or equivalent. 11. Remove nut and bolt retaining ball joint stud into steering knuckle. NOTE: Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get damaged. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 3826 12. Separate ball joint stud from steering knuckle by prying down on lower control arm. NOTE: Care must be taken not to separate the inner ON joint during this operation. Do not allow driveshaft to hang by inner ON joint, driveshaft must be supported. 13. Pull steering knuckle assembly out and away from outer C/V joint of the driveshaft assembly. 14. Support outer end of the driveshaft assembly. NOTE: Removal of the inner tripod joints is made easier if you apply outward pressure on the joint as you strike the punch with a hammer. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 3827 15. Remove the inner tripod joints from the side gears of the transaxle using a punch to dislodge the inner tripod joint retaining ring from the transaxle side gear. If removing the right side inner tripod joint, position the punch against the inner tripod joint. Strike the punch sharply with a hammer to dislodge the right inner joint from the side gear. If removing the left side inner tripod joint, position the punch in the groove of the inner tripod joint. Strike the punch sharply with a hammer to dislodge the left inner tripod joint from the side gear. 16. Hold inner tripod joint and interconnecting shaft of driveshaft assembly. Remove inner tripod joint from transaxle by pulling it straight out of transaxle side gear and transaxle oil seal. When removing tripod joint, do not let spline or snap ring drag across sealing lip of the transaxle to tripod joint oil seal. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 3828 Axle Shaft: Service and Repair Installation The content of this article reflects the changes called out by TSB 26-01-95. INSTALLATION CAUTION: The driveshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved an its wheels with a driveshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 183 Nm (135 ft lbs.). This will ensure that the hub bearing cannot loosen. 1. Thoroughly clean spline and oil seal sealing surface, on tripod joint. Lightly lubricate oil seal sealing surface on tripod joint with fresh clean transmission lubricant. 2. Holding driveshaft assembly by tripod joint and interconnecting shaft, install Tripod joint into transaxle side gear as far as possible by hand. 3. Carefully align tripod joint with transaxle side gears. Then grasp driveshaft interconnecting shaft and push tripod joint into transaxle side gear until fully seated. Test that snap ring is fully engaged with side gear by attempting to remove tripod joint from transaxle by hand. If snap ring is fully engaged with side gear tripod joint will not be removable by hand. 4. Clean all debris and moisture out of steering knuckle. 5. Ensure that front of outer C/V joint, which fits into steering knuckle, is free of debris and moisture before assembling into steering knuckle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 3829 6. Slide driveshaft back into front hub. Install steering knuckle onto the ball joint stud. 7. Install a NEW steering knuckle to ball joint stud clamping bolt and nut. Tighten the nut and bolt to 95 Nm (70 ft. lbs.). 8. Install tie rod end into steering knuckle. Start tie rod end to steering knuckle nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle nut. Then, using a crowfoot and 11/32 socket, tighten tie rod end nut to 61 Nm (45 ft. lbs.). 9. Install braking disc back on hub and bearing assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 3830 10. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding top of caliper under top abutment on steering knuckle. Then installing bottom of caliper against bottom abutment of steering knuckle. 11. Install caliper assembly to steering knuckle bolts. Tighten to 31 Nm (23 ft. lbs.). 12. Clean all foreign matter from threads of outer C/V joint stub axle. Install hub nut and washer onto the threads of the stub axle and tighten nut. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 3831 13. With vehicle brakes applied to keep axle shaft from turning, tighten hub nut to 183 Nm (135 ft. lbs.). 14. Install spring washer, hub nut lock and new cotter pin on outer C/V joint stub axle. Wrap the cotter pin prongs tightly around the hub nut lock. 15. Install front wheel and tire assembly. Install front wheel lug nuts and tighten to 135 Nm (100 ft. lbs.). 16. Check for correct fluid level in transaxle assembly. 17. Lower vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 3832 Axle Shaft: Service and Repair Overhaul NOTE: The only service that is to be performed on the driveshaft assemblies is the replacement of the driveshaft seal boots. If any failure of internal driveshaft components is diagnosed during a vehicle road test or disassembly of the driveshaft, the driveshaft will need to be replaced as an assembly. NOTE: Lubricant requirements and quantities are different for inner joints than for outer joints. Use only the recommended lubricants in the required quantities when servicing driveshaft assemblies. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot Replacement Constant Velocity Joint Boot: Service and Repair Inner Tripod Joint Sealing Boot Replacement Removal NOTES: - To remove sealing boot from driveshaft for replacement, the driveshaft assembly must be removed from the vehicle. - The inner tripod joints use no internal retention in the tripod housing to keep the spider assembly in the housing. Therefore, do not pull on the interconnecting shaft to disengage tripod housing from transmission stub shaft. Removal in this manner will cause damage to the inboard joint sealing boots. 1. Remove the driveshaft requiring boot replacement from the vehicle. 2. Remove large boot clamp that retains inner tripod joint sealing boot to tripod joint housing and discard. Then remove small clamp that retains inner tripod joint sealing boot to interconnecting shaft and discard. Remove the sealing boot from the tripod housing and slide it down the interconnecting shaft. CAUTION: When removing the spider joint from the tripod joint housing, hold the rollers in place on the spider bunions to prevent the rollers and needle bearings from falling away. 3. Slide the interconnecting shaft and spider assembly out of the tripod joint housing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot Replacement > Page 3837 4. Remove snap ring that retains spider assembly to interconnecting shaft. Remove the spider assembly from interconnecting shaft. If spider assembly will not come off interconnecting shaft by hand, it can be removed by tapping spider assembly with a brass drift. Do not hit the outer tripod bearings in an attempt to remove spider assembly from interconnecting shaft. 5. Slide sealing boot off interconnecting shaft. 6. Thoroughly clean and inspect spider assembly, tripod joint housing, and interconnecting shaft for any signs of excessive wear. If any parts show signs of excessive wear, the driveshaft assembly will require replacement. Component parts of these driveshaft assemblies are not serviceable. Installation NOTE: The inner tripod joint sealing boots are made from two different types of material. High-temperature applications use silicone rubber whereas standard temperature applications use Hytrel plastic. The silicone sealing boots are soft and pliable. The Hytrel sealing boots are stiff and rigid. The replacement sealing boot MUST BE the same type of material as the sealing boot that was removed. 1. Slide inner tripod joint seal boot retaining clamp, onto interconnecting shaft. Then slide the replacement inner tripod joint sealing boot onto interconnecting shaft. Inner tripod joint seal boot MUST be positioned on interconnecting shaft, so the raised bead on the inside of the seal boot is in groove on interconnecting shaft. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot Replacement > Page 3838 2. Install spider assembly onto interconnecting shaft with chamfer on spider assembly toward interconnecting shaft. Spider assembly must be installed on interconnecting shaft far enough to fully install spider retaining snap ring. If spider assembly will not fully install on interconnecting shaft by hand, it can be installed by tapping the spider body with a brass drift. Do not hit the outer tripod bearings in an attempt to install spider assembly on interconnecting shaft. 3. Install the spider assembly to interconnecting shaft retaining snap ring into groove on end of interconnecting shaft. Be sure the snap ring is fully seated into groove on interconnecting shaft. 4. Distribute 1/2 the amount of grease provided in the seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into tripod housing. Put the remaining amount into the sealing boot. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot Replacement > Page 3839 5. Align tripod housing with spider assembly and then slide tripod housing over spider assembly and interconnecting shaft. 6. Install inner tripod joint seal boot to interconnecting shaft clamp evenly on sealing boot. 7. Clamp sealing boot onto interconnecting shaft using crimper, Special Tool C-4975-A and the following procedure. Place crimping tool C-4975-A over bridge of clamp. Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face. CAUTION: Seal must not be dimpled, stretched, or out-of-shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand. 8. Position sealing boot into the tripod housing retaining groove. Install seal boot retaining clamp evenly on sealing boot. CAUTIONS: The following positioning procedure determines the correct air pressure inside the inner tripod joint assembly prior to clamping the sealing boot to inner tripod joint housing. If this procedure is not done prior to clamping sealing boot to tripod joint housing, boot durability can be adversely affected. - When venting the inner tripod joint assembly, use care so inner tripod sealing boot does not get punctured or, in any other way, damaged. If sealing boot is punctured or damaged while being vented, the sealing boot can not be used. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot Replacement > Page 3840 9. Insert a trim stick between the tripod joint and the sealing boot to vent inner tripod joint assembly, When inserting trim stick between tripod housing and sealing boot, ensure trim stick is held flat and firmly against the tripod housing. If this is not done, damage to the sealing boot can occur. If inner tripod joint has a Hytrel (hard plastic) sealing boot, be sure trim stick is inserted between soft rubber insert and tripod housing, and not the hard plastic sealing boot and soft rubber insert. 10. With trim stick inserted between sealing boot and tripod joint housing, position inner tripod joint on driveshaft until correct sealing boot edge to edge length is obtained for type of sealing boot material being used, Then remove the trim stick. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot Replacement > Page 3841 11. Clamp tripod joint sealing boot to tripod joint using required procedure for type of boot clamp application, If seal boot uses crimp type boot clamp, clamp sealing boot onto tripod housing using crimper, Special Tool C-4975-A. Place crimping tool C-4975-A over bridge of clamp. Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face-to-face. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot Replacement > Page 3842 12. If seal boot uses low profile latching type boot clamp, clamp sealing boot onto tripod housing using clamp locking tool, Snap-On YA3050 (or an equivalent). Place prongs of clamp locking tool in the holes of the clamp. Squeeze tool together until top band of clamp is latched behind the two tabs on lower band of clamp. 13. Install the Driveshaft requiring boot replacement back on the vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot Replacement > Page 3843 Constant Velocity Joint Boot: Service and Repair Outer CV Joint Sealing Boot Removal NOTE: To remove outer C/V joint sealing boot from a Driveshaft for replacement, the driveshaft assembly must be removed from the vehicle. 1. Remove driveshaft assembly requiring boot replacement from vehicle. 2. Remove large boot clamp retaining C/V joint sealing boot to C/V joint housing and discard. Remove small clamp that retains outer C/V joint sealing boot to interconnecting shaft and discard. Remove sealing boot from outer C/V joint housing and slide it down interconnecting shaft. 3. Wipe away grease to expose outer C/V joint and interconnecting shaft. 4. Remove outer C/V joint from interconnecting shaft using the following procedure: Support interconnecting shaft in a vise equipped with protective caps on jaws of vise to prevent damage to interconnecting shaft. Then, using a soft-faced hammer, sharply hit the end of the C/V joint housing to dislodge housing from internal circlip on interconnecting shaft. Then slide outer C/V joint off end of interconnecting shaft, joint may have to be tapped off shaft using a soft-faced hammer. 5. Remove large circlip from the interconnecting shaft before attempting to remove outer C/V joint sealing boot. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot Replacement > Page 3844 6. Slide failed sealing boot off interconnecting shaft. 7. Thoroughly clean and inspect outer C/V joint assembly and interconnecting joint for any signs of excessive wear. If any parts show signs of excessive wear, the driveshaft assembly will require replacement. Component parts of these driveshaft assemblies are not serviceable. Installation 1. Slide new sealing boot to interconnecting shaft retaining clamp onto interconnecting shaft. Slide the outer C/V joint assembly sealing boot onto the interconnecting shaft. Seal boot MUST be positioned on interconnecting shaft so the raised bead on the inside of the seal boot is in groove on interconnecting shaft. 2. Align splines on interconnecting shaft with splines on cross of outer C/V joint assembly and start outer C/V joint onto interconnecting shaft. 3. Install outer C/V joint assembly onto interconnecting shaft by using a soft-faced hammer and tapping end of stub axle (with nut installed) until outer C/V joint is fully seated on interconnecting shaft. 4. Outer C/V joint assembly must be installed on interconnecting shaft until cross of outer C/V joint assembly is seated against circlip on interconnecting shaft. 5. Distribute 1/2 the amount of grease provided in seal boot service package (DO NOT USE ANN OTHER TYPE OF GREASE) into outer C/V joint assembly housing. Put the remaining amount into the sealing boot. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot Replacement > Page 3845 6. Install outer C/V joint sealing boot to interconnecting shaft clamp evenly on sealing boot. 7. Clamp sealing boot onto interconnecting shaft using crimper, Special Tool C-4975-A, or equivalent and the following procedure. Place crimping tool C-4975-A, or equivalent over bridge of clamp. Tighten nut on crimping tool C-4975-A, or equivalent until jaws on tool are closed completely together, face to face. CAUTION: Seal must not be dimpled, stretched, or out-of-shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand. 8. Position outer C/V joint sealing boot into its retaining groove on outer C/V joint housing. Install sealing boot to outer Char joint retaining clamp evenly on sealing boot. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot Replacement > Page 3846 9. Clamp sealing boot onto outer C/V joint housing using Crimper, Special Tool C-4975-A, or equivalent and the following procedure. Place crimping tool C-4975-A, or equivalent over bridge of clamp. Tighten nut on crimping tool C-4975-A, or equivalent until jaws on tool are closed completely together, face to face. 10. Install the driveshaft requiring boot replacement back on the vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Front To Knuckle Retaining Nut .................................................................................................................... ................................................ 216 Nm (160 ft. lbs.) Rear Hub Nut ............................................................................................................................................... ................................................. 217 Nm (160 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 3851 Wheel Bearing: Fluid Type Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 3852 Wheel Bearing: Service Precautions CAUTION: The hub/bearing retaining nut must be tightened to but must not exceed its required torque specification. The proper torque specification of the retaining nut is critical to the life of the hub bearing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Description and Operation > Front Wheel Bearing: Description and Operation Front The front wheel hub bearing used is a Unit 1 type cartridge bearing. The wheel bearing is serviced separately from the front steering knuckle and front hub assembly. Installation and retention of the front wheel bearing into the steering knuckle, is by means of an interference press fit using a retaining compound and a retaining snap ring. Installation of the front hub into the front wheel bearing, must be done after wheel bearing and retaining snap ring is installed in steering knuckle. The unit 1 wheel bearing is serviced only as a complete assembly less the wheel hub. If the front wheel bearing requires replacement, the hub must be removed from the original wheel bearing and transferred to the replacement bearing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Description and Operation > Front > Page 3855 Wheel Bearing: Description and Operation Rear All vehicles are equipped with permanently lubricated and sealed for life rear wheel bearings. There is no periodic lubrication or maintenance recommended for these units. However, if servicing of a rear wheel bearing is required, refer to procedures in Testing and Inspection and Service and Repair for the inspection and replacement of the rear wheel bearing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Front Wheel Bearing: Testing and Inspection Front NOTE: The hub bearing is designed for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the hub bearing. With the wheel, disc brake caliper. and brake rotor removed, rotate the wheel hub. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the hub bearing exhibits any of these conditions during diagnosis, the hub bearing will require replacement, the bearing is not serviceable. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weapage from the hub bearing is considered normal and should not require replacement of the hub bearing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 3858 Wheel Bearing: Testing and Inspection Rear The rear hub and bearing assembly is designed for the life of the vehicle and should require no maintenance. The following procedure may be used for evaluation of bearing condition. With wheel and brake drum removed, rotate flanged outer ring of hub. Excessive roughness, lateral play or resistance to rotation may indicate dirt intrusion or bearing failure. If the rear wheel bearings exhibit these conditions during inspection, the hub and bearing assembly should be replaced. Damaged bearing seals and resulting excessive grease loss may also require bearing replacement. Moderate grease loss from bearing is considered normal and should not require replacement of the hub and bearing assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Removal 1. Remove the steering knuckle, hub and the hub bearing as an assembly from the vehicle. See: Steering and Suspension/Steering/Front Steering Knuckle/Service and Repair NOTE: The removal and installation of the steering knuckle hub bearing is to ONLY be done with the steering knuckle removed from the vehicle. Removal of the hub bearing from the steering knuckle MUST be done using an arbor press and the following procedure. 2. Install Bearing Splitter, Special Tool P334, or equivalent on the steering knuckle and hub/bearing assembly as shown to support steering knuckle when pressing out hub. 3. Position steering knuckle and hub and bearing in an arbor press supported by Bearing Splitter, Special Tool P334 as shown. 4. Position Driver, Special Tool 6644-2, or equivalent on the small end of the hub to drive hub out of bearing. Using arbor press remove hub from bearing. The one bearing race will come out with hub when hub is removed from bearing. 5. Remove Bearing Splitter, Special Tool P334, or equivalent from the steering knuckle. CAUTION: Safety goggles and or face protection should always be worn when removing the snap ring retaining the hub/bearing in the steering knuckle. When the snap ring is removed from the steering knuckle it could fly out of the steering knuckle with great force possibly causing personal injury. 6. Using a screw driver, remove the snap ring retaining the hub bearing in the steering knuckle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3861 7. Place steering knuckle in an arbor press supported by press blocks as shown. Press blocks must not obstruct hub bearing bore in steering knuckle so bearing can be pressed out of knuckle. Place Bearing Driver, Special Tool MB-990799, or equivalent on outer race of hub bearing. Press hub bearing completely out of the steering knuckle. 8. Install Bearing Splitter, Special Tool P334, or equivalent on hub so it is between the flange of the hub and the bearing race remaining on the hub. Place hub, bearing race and the bearing splitter in an arbor press as shown. Place Driver, Special Tool 6644-2, or equivalent on end of hub. Press the hub out of the bearing race. Installation 1. Wipe bore of steering knuckle clean of any grease or dirt with a clean dry shop towel. CAUTIONS: Do not use any type of solvent on the hub bearing when cleaning it. - The hub bearing must be wiped as clean as possible. Any remaining rust preventative on the bearing can effect the bonding action of the adhesive to the bearing. 2. Clean the rust preventative from the replacement hub bearing using a clean dry shop towel. CAUTION: When applying adhesive to bore of steering knuckle, do not allow adhesive to get into the snap ring in bore or on the seal of the hub bearing 3. Apply Loctite Adhesive #640 or an equivalent, to the bore of the steering knuckle. The adhesive is to be applied to the entire bore wall surface, from the shoulder at the bottom to just below the snap ring groove. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3862 4. Place new hub bearing into bore of steering knuckle so it is square with the bore. Place steering knuckle in arbor press with Receiver, Special Tool C-4698-2, or equivalent supporting steering knuckle. Place Diver, Special Tool 5052, or equivalent on outer race of the hub bearing. Press hub bearing into steering knuckle until it is fully bottom in bearing bore of steering knuckle. CAUTION: When installing the retaining snap ring for the hub bearing care must be taken not to damage seal on new hub bearing. 5. Install hub bearing retaining snap ring into snap ring groove in hub bearing bore of steering knuckle. Be sure snap ring is fully seated in snap ring groove. 6. Place steering knuckle with hub bearing installed in an arbor press with Receiver, Special Tool MB-990799, or equivalent supporting inner race of the hub bearing. Place hub in nub bearing making sure it is square with bearing. Place Driver, Special Tool 6522, or equivalent on front face of hub. Press the hub into the hub bearing until hub is fully bottomed in hub bearing. 7. Install the steering knuckle, hub and the hub bearing as an assembly on the vehicle. See: Steering and Suspension/Steering/Front Steering Knuckle/Service and Repair 8. Install the wheel and tire on the vehicle. 9. Lower the vehicle. 10. Set the front wheel Toe to the required specification. CAUTION: After the vehicle is aligned it can only be moved a short distance and then parked. Do not move the vehicle any further until the adhesive has cured for a minimum of two hours. Driving the vehicle before the adhesive is allowed to cure properly, will affect the retention of the Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3863 bearing in the bore of the steering knuckle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3864 Wheel Bearing: Service and Repair Rear REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. On vehicles equipped with rear drum brakes, remove brake drum from rear hub/bearing assembly. On vehicles equipped with rear disc brakes, remove disc brake caliper from disc brake adapter, and then remove rotor from hub/ bearing assembly. Rear Hub And Bearing Dust Cap 4. Remove dust cap. from rear hub/bearing assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3865 5. Remove hub/bearing assembly to rear spindle retaining nut. 6. Remove rear hub/bearing assembly from rear spindle by pulling straight of spindle by hand. INSTALL CAUTION: The hub/bearing retaining nut must be tightened to but must not exceed its required torque specification. The proper torque specification of the retaining nut is critical to the life of the hub bearing. 1. Position hub/bearing assembly on rear spindle. 2. Install a new hub nut and tighten to a torque of 217 Nm (160 ft. lbs.). 3. Install dust cap; using a soft faced hammer. 4. On drum brake equipped vehicles, install rear brake drum on hub/bearing assembly. On vehicles equipped with rear disc brakes, install rotor on hub/ bearing assembly. Caliper Assembly Guide Pin Bolts 5. On disc brake equipped vehicles install disc brake caliper on disc brake adapter. Install the 2 caliper guide pin bolts and torque to 22 Nm (192 in. lbs.). Refer To Disc Brake Caliper Service and Repair. 6. Install rear wheel and tire assembly on vehicle. Tighten all wheel stud nuts in crisscross pattern to one-half specified torque. Then repeat pattern, fully tightening stud nuts to 109 - 150 Nm (80 - 110 ft. lbs.). 7. Lower vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 3875 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 3881 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 3882 Axle Nut: Specifications Front Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 183 Nm (135 ft. lbs.) Rear Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 217 Nm (160 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications To Crankshaft Bolts ............................................................................................................................. ..................................................... 95 Nm (70 ft. lbs.) To Torque Converter Bolts ............................... ........................................................................................................................................ 68 Nm (50 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications To Crankshaft Bolts ............................................................................................................................. ..................................................... 95 Nm (70 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation CIRCUIT OPERATION The PRNDL lamp receives power on the E2 circuit from the 4 Amp fuse located in the fuse block in cavity 12. The fuse receives power from the headlamp switch. Circuit E2 also powers the ash receiver lamp. When the headlamp switch is moved to the PARK or ON position, current flows through the fuse to the PRNDL lamp. The ground for the lamp is supplied on the Z3 circuit, and terminates at the instrument panel left center support. This circuit is also spliced in with the ash receiver lamp, the ignition switch lamp, and the glove box lamp. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Service and Repair Transmission Mode Indicator - A/T: Service and Repair REMOVAL Floor Console With Transmission Range Indicator 1. Raise the floor console. 2. Remove the attaching screw from each of the two forward cup holders of the floor console. Remove the screws at the rear of the console or inside of the armrest console bin. 3. Pull the parking brake lever all the way up. 4. Lift the floor console at the rear high enough to gain access to the lamp and socket. 5. Remove the indicator lamp socket from bezel to replace the lamp. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Specifications Bell Housing: Specifications To Engine Bolts ................................................................................................................................... ..................................................... 95 Nm (70 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Specifications Case: Specifications End Plate Cover Bolts ......................................................................................................................... ..................................................... 29 Nm (21 ft. lbs.) Attaching Bolts ................................................. ........................................................................................................................................ 29 Nm (21 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Ring Gear, M/T > Component Information > Specifications Ring Gear: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 81 Nm (60 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Drain Plug, M/T > Component Information > Specifications Drain Plug: Specifications Mounting .............................................................................................................................................. ............................................... 30 Nm (267 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid .............................................................................................................................. ............................................. 1.9-2.2L (4.0-4.6 Pints) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 3915 Fluid - M/T: Fluid Type Specifications Transmission Fluid MOPAR type M.S. 9417 Manual Transaxle Fluid Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Specifications Output Shaft: Specifications Bearing Race Retaining Strap ............................................................................................................. .................................................. 11 Nm (96 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Reverse Gear Shaft > Component Information > Specifications Reverse Gear Shaft: Specifications Mounting Bolt ....................................................................................................................................... ................................................... 26 Nm (19 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Shift Shaft Seal Replacement Seals and Gaskets: Service and Repair Shift Shaft Seal Replacement NOTE: It is not necessary to remove the shift shafts from the transaxle to service the shift shaft seals. REMOVAL Using a pick tool, pry up on the shift shaft seal and remove seal from bore. INSTALLATION 1. Position new shift shaft seal in bore. 2. Install shift shaft seal into bore using an appropriate size deep-well socket. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Shift Shaft Seal Replacement > Page 3926 Seals and Gaskets: Service and Repair Transaxle Side Seal Replacement NOTE: The axle shaft seals are identical for both sides of the differential and will interchange. REMOVAL 1. Remove axle shaft. 2. Insert a flat-blade pry tool at outer edge of axle shaft seal. 3. Tap on the pry tool with a small hammer and remove axle shaft seal. INSTALLATION 1. Clean axle shaft seal bore of any excess sealant. 2. Align axle shaft seal with axle shaft seal bore. 3. Install axle seal on tool # 6709 and C-4171, or equivalents and insert into axle shaft seal bore. 4. Tap seal into position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Gearshift Knob Replacement Shifter M/T: Service and Repair Gearshift Knob Replacement REMOVAL 1. Pull shifter boot down and away from shifter roll pin. 2. Pry legs of shift knob away from shift lever roll pin using a flat blade pry tool. 3. Remove knob from shifter handle. INSTALLATION For installation, reverse removal procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Gearshift Knob Replacement > Page 3931 Shifter M/T: Service and Repair Gearshift Boot Replacement REMOVAL 1. Remove shifter knob. 2. Remove the console assembly. 3. Snip the plastic retaining clips at the base of the boot. Remove the boot from the gearshift mechanism. INSTALLATION For installation, reverse removal procedure. Install new plastic retaining clips. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Gearshift Knob Replacement > Page 3932 Shifter M/T: Service and Repair Gearshift Mechanism Replacement REMOVAL 1. Remove shifter knob. 2. Remove console assembly. 3. Remove shifter boot. 4. Remove gearshift cables. 5. Remove the parking brake mechanism. Refer to Brakes and Traction Control for procedure. 6. Remove the airbag control module. Refer to Air Bags and Seat Belts for procedure. 7. Remove the two remaining nuts at the base of the gearshift mechanism. Remove shifter. INSTALLATION For installation, reverse removal procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications Shift Cable: Specifications Crossover Cable Adjustment Screw .................................................................................................... ........................................................... 8 Nm (70 inch) Bracket To Transaxle ...................................... .................................................................................................................................... 28 Nm (250 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications > Page 3937 Shift Cable: Adjustments The gearshift selector cable is not adjustable. If adjustment is required, only the crossover cable may be adjusted. 1. Remove gearshift console from vehicle. Gearshift Crossover Cable Adjustment 2. Loosen crossover cable adjustment screw. Crossover Lever Attachment To Transaxle 3. Using a 1/4 inch drill bit or suitable equivalent, pin crossover cable lever to transaxle. Ensure drill bit engages through crossover lever into transaxle case at least one half inch. 4. Ensure shift lever is in the spring loaded neutral position. If necessary, move lever forward and back, then allow lever to fall into it's natural neutral position. 5. Without allowing movement in either cable or lever, hand tighten crossover cable adjustment screw, then tighten screw to specifications. 6. Remove pin from transaxle crossover lever, then check transaxle shift functions. 7. Install gearshift console. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications > Page 3938 Shift Cable: Service and Repair NOTE: Use this procedure if either of the shift cables require replacement. REMOVAL AND INSTALLATION 1. Disconnect Power Distribution Center from battery tray and set aside. 2. Remove air cleaner inlet horn. 3. Remove battery and battery tray. Shift Cable Removal 4. Disconnect gear shift cable ends from transaxle shift levers. CAUTION: Pry up with equal force on both sides of shifter cable isolator bushings to avoid damaging cable isolator bushings. 5. Remove cable to bracket retaining clips at transaxle. CAUTION: It is recommended that new cable retaining clips be used for reinstallation. 6. Pull cables up out of transaxle bracket. 7. Remove console from vehicle. Cable Retaining Clips 8. Remove floor pan grommet retaining nuts. 9. Remove cable retaining clips at shifter. CAUTION: It is recommended that new cable retaining clips be used for reinstallation. 10. Disconnect shift cables from shifter. Pry with equal force on both sides of shifter cable isolator bushings to avoid damaging bushings. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications > Page 3939 Shift Cable Floor Grommet 11. Lift vehicle on hoist. Remove self tapping screws securing grommet plate to underbody heat shield and floor pan. 12. Detach cables from cable support clip in tunnel above exhaust catalyst. 13. Remove shift cables from vehicle. To install, reverse removal procedure. After cables have been replaced, cable adjustment should be checked. CAUTION: Only the crossover cable is adjustable. The selector cable does not have any adjustment capabilities. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Speedometer Gear, M/T > Component Information > Service and Repair Speedometer Gear, M/T: Service and Repair REMOVAL 1. Raise vehicle on hoist. 2. Remove wiring connector from speed sensor. CAUTION: Clean area around speed sensor before removing. This prevents the possibility of dirt from entering the transaxle during speed sensor removal. 3. Remove speed sensor retaining bolt. 4. Remove speed sensor from transaxle. CAUTION: Carefully remove vehicle speed sensor so that sensor drive gear does not fall into transaxle. Should sensor drive gear fall into the transaxle during sensor removal, drive gear must be reattached to sensor. 5. Remove speed sensor drive gear from speed sensor. INSTALLATION 1. To install, reverse removal procedure. 2. Confirm vehicle speedometer is functioning properly following installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Throttle Position Sensor Mounting Screws 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3953 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3954 Transmission Position Switch/Sensor: Description and Operation Fig. 20 Park/Neutral Switch OPERATION On vehicles with 3-speed automatic transmission the park/neutral switch provides an input to the Powertrain Control Module (PCM). The park/neutral position switch is located on the automatic transaxle housing Fig. 20. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. CIRCUIT OPERATION When CLOSED the Transmission Range Switch (TRS) provides an input to the Powertrain Control Module (PCM) on circuit T41. This circuit connects to cavity 76 of the PCM connector. The T41 circuit is spliced and provides a ground path for the engine starter relay, and the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations The Torque Converter Clutch Solenoid is located on the Valve Body. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3963 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3964 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3965 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3966 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3967 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3968 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3969 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3970 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3971 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3972 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3973 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3974 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3975 Torque Converter Clutch Solenoid: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3976 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3977 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3978 Connector Pin-Outs (Part 31 Of 32) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3979 Fuel And Ignition Diagrams (Part 8 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 3980 Torque Converter Clutch Solenoid: Description and Operation If the solenoid wiring connector is unplugged, the torque converter will not engage. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation CIRCUIT OPERATION The PRNDL lamp receives power on the E2 circuit from the 4 Amp fuse located in the fuse block in cavity 12. The fuse receives power from the headlamp switch. Circuit E2 also powers the ash receiver lamp. When the headlamp switch is moved to the PARK or ON position, current flows through the fuse to the PRNDL lamp. The ground for the lamp is supplied on the Z3 circuit, and terminates at the instrument panel left center support. This circuit is also spliced in with the ash receiver lamp, the ignition switch lamp, and the glove box lamp. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Service and Repair Transmission Mode Indicator - A/T: Service and Repair REMOVAL Floor Console With Transmission Range Indicator 1. Raise the floor console. 2. Remove the attaching screw from each of the two forward cup holders of the floor console. Remove the screws at the rear of the console or inside of the armrest console bin. 3. Pull the parking brake lever all the way up. 4. Lift the floor console at the rear high enough to gain access to the lamp and socket. 5. Remove the indicator lamp socket from bezel to replace the lamp. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Throttle Position Sensor Mounting Screws 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3999 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4000 Transmission Position Switch/Sensor: Description and Operation Fig. 20 Park/Neutral Switch OPERATION On vehicles with 3-speed automatic transmission the park/neutral switch provides an input to the Powertrain Control Module (PCM). The park/neutral position switch is located on the automatic transaxle housing Fig. 20. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. CIRCUIT OPERATION When CLOSED the Transmission Range Switch (TRS) provides an input to the Powertrain Control Module (PCM) on circuit T41. This circuit connects to cavity 76 of the PCM connector. The T41 circuit is spliced and provides a ground path for the engine starter relay, and the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation ANTILOCK BRAKE SYSTEM (ABS) AMBER WARNING LAMP The ABS system uses an Amber ABS Warning Lamp, located in the instrument cluster. The purpose of the warning lamp is discussed in detail below. When Detection Occurs The ABS warning lamp will turn on when the Controller Antilock Brake (CAB) detects a condition which results in a shutdown of ABS function. The ABS Warning Lamp is normally on until the CAB completes its self tests and turns the lamp off (approximately 4-5 seconds after the ignition switch is turned on). When the ABS warning lamp is on, only the ABS function of the brake system if affected. The standard brake system and the ability to stop the car will not be affected when only the ABS warning lamp is on. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Locations System Relay And Pump Motor Relay Box Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Description and Operation > ABS System Relay ABS Main Relay: Description and Operation ABS System Relay CIRCUIT OPERATION The system relay is used for the operation of the Anti Lock Brake (ABS) system. Power for the relay is supplied on the B57 circuit from cavity 57 of the Controller Anti Lock Brake (CAB). Ground for the relay is on the Z1 circuit. This ground is spliced in with the pump motor and terminates at the left headlamp ground. When the system is operating normally power for the contact side of the relay is supplied from the CAB on the B57 circuit. It passes through the relay to the Z1 ground and terminates at the left headlamp ground. If a problem is detected in the system, the contact side of the relay switches from the Z1 to the F12 circuit. This causes the ABS warning lamp in the instrument cluster to illuminate. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Description and Operation > ABS System Relay > Page 4011 ABS Main Relay: Description and Operation ABS System Relays System Relay And Pump Motor Relay Box SYSTEM RELAY The main purpose of the system relay is to put the Antilock Brake System (ABS) into a stand-by mode for ABS operation. The System Relay is energized by the Controller Antilock Brake (CAB) shortly after the ignition switch is turned on. When Energized - by the CAB, the System Relay turns off the ABS warning lamp and provides 12 volts to the CAB. This voltage can then be used by the CAB to energize the Decay Solenoids during ABS braking. When energized, the System Relay also provides the Pump/Motor Relay coil with 12 volts. The ground path to the Pump/Motor Relay is completed by the CAB during ABS braking. When De-energized - the ABS warning lamp is illuminated, voltage to the Decay Solenoids is cut off, and the Pump/Motor Relay is prevented from energizing. Typically, the System Relay is de-energized by the CAB when a fault is detected that requires turning ABS off. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Locations System Relay And Pump Motor Relay Box Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Locations > Page 4015 Brake Fluid Pump: Description and Operation HYDRAULIC CONTROL UNIT (HCU) PUMP MOTOR ASSEMBLY The HCU contains 2 Pump Assemblies, one each for the primary and secondary hydraulic circuits. Both pumps are driven by a common electric motor which is part of the Hydraulic Control Unit (HCU). The pumps pick up fluid from the sumps to supply build pressure to the brakes during an Antilock Brake System (ABS) stop. The motor only runs during an ABS stop and is controlled by the Controller Antilock Brakes (CAB) via the Pump/Motor Relay. The Pump/Motor Assembly is not a serviceable item. If it requires service the HCU must be replaced. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump Relay > Component Information > Description and Operation > Description Brake Fluid Pump Relay: Description and Operation Description System Relay And Pump Motor Relay Box PURPOSE Pump/Motor power is supplied by the Pump/Motor Relay. The pump motor relay is also part of the relay box mounted to the Hydraulic Control Unit (HCU). If pump/motor relay replacement is required, it is also only serviced by the replacement of the relay box assembly. FUNCTION Voltage for the 12 volt side of the relay coil is provided by the System Relay. The ground path through the relay coil is completed by the Controller Antilock Brake (CAB) during Antilock Brake System (ABS) braking. The relay contacts are closed when the relay is energized. This provides 12 volts to the pump/motor as needed during ABS braking. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump Relay > Component Information > Description and Operation > Description > Page 4020 Brake Fluid Pump Relay: Description and Operation Circuit Operation CIRCUIT OPERATION The Anti Lock Brake (ABS) pump motor relay controls when the pump motor runs. Power for the coil side of the relay is supplied from cavity 47 of the Controller Anti Lock Brake (CAB) on the B47 circuit. This circuit also supplies voltage for the contact side of the system relay The ground side of the coil is controlled by the B116 circuit. Circuit B116 connects to cavity 16 of the CAB connector. Circuit B120 from cavity 20 of the CAB connector powers the ABS pump motor. This circuit is also used as an input to the CAB for pump motor monitoring. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Description and Operation Braking Sensor/Switch: Description and Operation CIRCUIT OPERATION Circuit L50 is an input to the Controller Anti Lock Brake (CAB). The L50 connects to cavity 13 of the CAB connector. Circuit L50 is spliced in with the stop lamps and is used to provide the CAB with information on when the brakes are being applied. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations Diagnostic Connector - ABS: Locations Controller Antilock Brake On this vehicle, the ABX-4 brake system (DRB) diagnostic connector is located under the steering column cover, directly below the steering column. The ABX-4 system uses the ISO 9141-K connector which is shared by other vehicle diagnostic systems such as the powertrain control module and air bag. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > Page 4027 Diagnostic Connector - ABS: Description and Operation CIRCUIT OPERATION Circuit D21 is used for diagnostics of a fault with the Antilock Brake (ABS) system. It is spliced in with the Powertrain Control Module (PCM) circuits and used as an output from the Controller Anti Lock Brake (CAB). Circuit D21 connects to cavity 51 of the CAB connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > Page 4028 Diagnostic Connector - ABS: Testing and Inspection - Check the 15 Amp fuse located in cavity 10 of the fuse block. - Check the 40 Amp fuse located in the PDC. - Check for a good ground at the left headlamp ground. - Check the case ground on the CAB Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations CAB 60-Way Wiring Harness Connector Controller Antilock Brake The CAB is mounted under the instrument panel behind the drivers side kick panel of the vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4032 Electronic Brake Control Module: Description and Operation Controller Antilock Brake PURPOSE The Controller Antilock Brake (CAB) is a microprocessor based device which monitors the Antilock Brake System (ABS) during normal braking and controls it when in an ABS stop. The CAB is mounted under the instrument panel on the drivers side kick panel. The CAB uses a 60 way electrical connector on the vehicle wiring harness. The power source for the CAB is through the ignition switch in the Run or On position. NOTE: The CAB is not on the Chrysler Collision Detection (CCD) bus. THE PRIMARY FUNCTIONS OF THE CAB - Detect wheel locking tendencies. - Control fluid modulation to the brakes while in ABS mode. - Monitor the system for proper operation. - Provide communication to the DRB scan tool while in diagnostic mode. The CAB Continuously Monitors - the speed of each wheel through the signals generated at the Wheel Speed Sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the CAB commands the Hydraulic Control Unit (HCU) to modulate brake fluid pressure in some or all of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The ABS System Is Constantly Monitored - by the CAB for proper operation. If the CAB detects a fault, it will turn on the Amber ABS Warning Lamp and disable the ABS braking system. The normal Non ABS braking system will remain operational. The CAB Contains A Self-diagnostic Program - which will turn on the Amber ABS Warning Lamp when a ABS system fault is detected. Faults Are Then Stored - in a diagnostic program memory. There are multiple fault messages which may be stored in the CAB and displayed through the DRB. These fault messages will remain in the CAB memory even after the ignition has been turned off. The fault messages can be cleared by using the DRB diagnostics tester, or they will be automatically cleared from the memory after the vehicle is driven approximately 3500 miles. CONTROLLER ANTILOCK BRAKE INPUTS ^ Four wheel speed sensors. ^ Stop lamp switch. ^ Ignition switch. ^ System relay voltage. ^ Ground. ^ Pump/Motor Relay Monitor ^ Diagnostics Communications CONTROLLER ANTILOCK BRAKE OUTPUTS ^ 4 Decay Solenoids ^ ABS warning lamp. ^ System relay actuation. ^ Diagnostic communication. ^ Pump motor relay actuation Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4033 Electronic Brake Control Module: Service and Repair Controller Antilock Brake REMOVE 1. Turn vehicle ignition off. CAB 60-Way Wiring Harness Connector 2. Disconnect the wiring harness 60 way connector from the Controller Antilock Brake Module (CAB). Verify that the vehicle ignition is off before removing the 60 way connector. CAB Bracket To Kick Panel Mounting 3. Remove the 2 controller bracket to drivers side cowl mounting nuts. 4. Remove the CAB from the vehicle. INSTALL 1. Install CAB and mounting bracket on mounting studs located on passenger side kick panel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4034 2. Install the 2 CAB bracket mounting nuts and securely tighten. 3. Install the 60-way wiring harness connector by hand into the 60-way CAB connector, as far as possible. Then use the CAB connector retaining bolt to fully seat wiring harness connector into the CAB. 4. Torque the 60-way connector retaining bolt to 4 Nm (38 inch lbs.). 5. If a new CAB is being has been installed, it must be initialized prior to the vehicle being driven. The CAB is initialized using the DRB Scan Tool and the initializing procedure described upon selecting Bendix ABX-4 Diagnostics. New controllers are programmed to flash the ABS warning lamp until initialized by the installing technician. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Specifications Hydraulic Control Unit: Specifications To Mounting Bracket Bolts .................................................................................................................. ............................................... 28 Nm (250 inch lbs.) Bracket To Frame Rail Mounting Bolt (Top) ...................................................................................................................................... 18 Nm (160 inch lbs.) Bracket To Frame Rail Mounting Bolts (Side) ................................................................................................................................... 22 Nm (200 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Specifications > Page 4038 Hydraulic Control Unit Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Specifications > Page 4039 Hydraulic Control Unit: Service Precautions WARNING: THE ONLY PARTS OF THE HYDRAULIC CONTROL UNIT (HCU) THAT ARE SERVICEABLE ARE THE RELAY BOX, THE PROPORTIONING VALVES, AND THE HCU MOUNTING BRACKET. THE REMAINING COMPONENTS OF THE HYDRAULIC CONTROL UNIT HCU ARE NOT SERVICEABLE ITEMS. NO ATTEMPT SHOULD EVER BE MADE TO REMOVE OR SERVICE ANY OTHER PARTS OF THE HYDRAULIC CONTROL UNIT HCU. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > General Information Hydraulic Control Unit: Description and Operation General Information Hydraulic Control Unit GENERAL INFORMATION The Hydraulic Control Unit (HCU) is located under the master cylinder and power brake booster and is mounted to the left frame rail. The HCU contains the following components for controlling the vehicle's braking system during Antilock Brake System (ABS) braking: 4 Decay Valves, 4 Shuttle Valves, 2 Fluid Sumps, a Pump/Motor and a relay box. Also attached to the HCU are the rear brake Proportioning Valves and the vehicles 6 hydraulic brake tubes. Decay Solenoids There are 4 decay solenoids, one for each wheel. In the released position they provide a fluid path from the master cylinder to the wheel brakes of the vehicle. In the actuated (decay) position, they provide a fluid path from wheel brakes of the vehicle to the sumps. The Decay solenoids are spring loaded in the released (build) position during normal braking. Shuttle Valves There are 4 Shuttle Valves, one for each wheel. The Shuttle Valve is a hydraulically actuated valve which shuttles when the decay solenoid and pump are energized. This places an orifice (restriction) in the line between the pump and the decay solenoid. This restriction provides a controlled build rate to each wheel brake during an ABS stop. The Shuttle Valve will remain in the orificed position until the ABS cycle is complete. When the ABS cycle has been completed the decay solenoids will return to their released position which will equalize the pressure across the Shuttle Valves. When the pressure equalizes, the spring loaded Shuttle Orifice valves will return to the unrestricted position. Fluid Sumps There are two fluid sumps in the HCU, one each for the primary and secondary hydraulic circuits. The fluid sumps temporarily store brake fluid that is decayed from the wheel brakes during an ABS cycle. This fluid is then delivered to the pump to provide build pressure. The typical pressure in the sumps is 50 psi, during ABS operation only. Pump Motor Assembly The HCU contains 2 Pump Assemblies, one each for the primary and secondary hydraulic circuits. Both pumps are driven by a common electric motor which is part of the HCU. The pumps pick up fluid from the sumps to supply build pressure to the brakes during an ABS stop. The motor only runs during an ABS stop and is controlled by the Controller Antilock Brake (CAB) via the Pump/Motor Relay. The Pump/Motor Assembly is not a serviceable item. If it requires service the HCU must be replaced. Relay Box ABX-4 utilizes two relays contained in a relay box mounted to the HCU. The relay box contains a System Relay and a Pump/Motor Relay. A single 10-way connector provides the electrical interface. The relay box is serviceable as an assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > General Information > Page 4042 Hydraulic Control Unit: Description and Operation Hydraulic Control Unit Decay Solenoids HYDRAULIC CONTROL UNIT DECAY SOLENOIDS There are 4 decay solenoids, one for each wheel. In the released position they provide a fluid path from the Master Cylinder to the wheel brakes of the vehicle. In the actuated (decay) position, they provide a fluid path from wheel brakes of the vehicle to the sumps. The Decay Solenoids are spring loaded in the released (build) position during normal braking. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > General Information > Page 4043 Hydraulic Control Unit: Description and Operation Hydraulic Control Unit Shuttle Valves HYDRAULIC CONTROL UNIT SHUTTLE VALVES There are 4 Shuttle Valves, one for each wheel. The Shuttle Valve is a hydraulically actuated valve which shuttles when the decay solenoid and pump are energized. This places an orifice (restriction) in the line between the pump and the decay solenoid. This restriction provides a controlled build rate to each wheel brake during an ABS stop. The Shuttle Valve will remain in the orificed position until the ABS cycle is complete. When the ABS cycle has been completed the decay solenoids will return to their released position which will equalize the pressure across the Shuttle Valves. When the pressure equalizes, the spring loaded Shuttle Orifice valves will return to the unrestricted position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > General Information > Page 4044 Hydraulic Control Unit: Description and Operation Hydraulic Modulator Circuit Operation CIRCUIT OPERATION The hydraulic modulator is used for the controlling of the brake system pressure to the wheels. The modulator is made up of four solenoids. Circuits involved are, B142 for the left front wheel, B143 for the right front wheel, B146 for the left rear wheel, and B148 for the right rear wheel. The solenoids use a common ground on the Z1 circuit. There are two Z1 circuits from the modulator. Both of these grounds terminate at the left headlamp ground, and are spliced in with the Anti Lock Brake System (ABS) pump motor and the ABS system relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement Hydraulic Control Unit: Service and Repair Hydraulic Control Unit (HCU) Replacement Removal PROCEDURE 1. Disconnect negative (ground) cable from the battery and isolate cable. Master Cylinder Fluid Level Sensor 2. Disconnect vehicle wiring harness connector from brake fluid level sensor at base of master cylinder brake fluid reservoir. Fig 7 Type 3 Primary And Secondary Output Ports. With ABS 3. Disconnect primary and secondary brake tubes from master cylinder housing. Install plugs at brake tube outlets of master cylinder assembly. 4. Clean area where master cylinder attaches to booster using a suitable brake cleaner. CAUTION: On ABS equipped vehicles, vacuum in power booster must be pumped down before removing master cylinder to prevent the booster from sucking in any contamination. This can be done simply by pumping the brake pedal, with the engine not running, until a firm brake pedal is achieved. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4047 Master Cylinder Mounting To Vacuum Booster 5. Remove the 2 nuts attaching master cylinder to power brake booster unit. 6. Slide master cylinder assembly straight out, and away from power brake booster unit. Electrical Connections To HCU And Relay Box 7. Disconnect the 6 way connector from the Hydraulic Control Unit (HCU) wiring harness and 10 way connector from the relay box located on the HCU. Primary And Secondary Brake Tubes From Master Cylinder To HCU 8. Remove the primary and secondary master cylinder brake tubes from the HCU. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4048 Proportioning Valve Location On Hydraulic Control Unit 9. Remove the chassis brake tubes from the proportioning valves and outlet ports of the (HCU). 10. Raise vehicle. Hydraulic Control Unit Mounting Bracket 11. Loosen and remove the 2 bolts attaching the HCU mounting bracket to the side of the front frame rail. 12. Lower vehicle. 13. Loosen and remove the bolts attaching the HCU mounting bracket to the top of the frame rail. 14. Remove HCU and its mounting bracket as an assembly from the vehicle. Installation PROCEDURE Hydraulic Control Unit Mounting Bracket 1. Install the Hydraulic Control Unit (HCU) and mounting bracket as an assembly, on left front frame rail of the vehicle, aligning tabs on mounting bracket with holes in frame rail. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4049 2. Install and loosely tighten the bolt attaching the HCU mounting bracket to the top of the frame rail. 3. Raise vehicle. 4. Install the 2 bolts attaching the HCU mounting bracket to the side of the front frame rail. Then torque both mounting bolts to 28 Nm (200 inch lbs.). 5. Lower vehicle. 6. Torque bolt attaching HCU mounting bracket to top of frame rail to 20 Nm (180 inch lbs.). Proportioning Valve Location On Hydraulic Control Unit 7. Install the 4 chassis brake tubes onto the proportioning valves and outlet ports of the HCU. Torque the 4 chassis brake tube nuts to 17 Nm (145 inch lbs.). Primary And Secondary Brake Tubes From Master Cylinder To HCU 8. Install primary and secondary brake tubes from the master cylinder onto the HCU, with tube nuts only hand tightened. Electrical Connections To HCU And Relay Box 9. Install vehicle wiring harness connectors onto the 10 way, and 6 way connectors, located on the relay box of the HCU. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4050 Removing Seal From Vacuum Booster 10. Remove vacuum seal located in the front of the power brake vacuum booster. Vacuum seal is removed by carefully inserting a small screw driver between the push rod of the power brake vacuum booster and vacuum seal and pry seal out of power brake vacuum booster. Do not attempt to pry seal out of master cylinder by inserting a tool between seal and power brake vacuum booster. 11. Remove old vacuum seal from master cylinder, if the vacuum seal came out of power brake vacuum booster when master cylinder was removed this step is not necessary. CAUTION: When replacing the master cylinder on a vehicle equipped with ABS, a NEW vacuum seal MUST be installed in the power brake vacuum booster. Use only the procedure detailed below for installing vacuum seal into power brake vacuum booster. Be sure old vacuum seal is removed from power brake vacuum booster before attempting to install new seal. CAUTION: When lubricating master cylinder push rod, use only Mopar Silicone Dielectric Compound. Using any other type of grease or lubricant on the push rod, will not provide adequate long term lubrication of the push rod. Lubricating Master Cylinder Push Rod 12. Lubricate master cylinder push rod as indicated only using Mopar Dielectric Grease-And No Substitutes. Fig 19 Type 3 Vacuum Seal Installation. Neon Models Equipped With ABS Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4051 Fig 20 Type 3 Vacuum Seal Seating. Neon Models Equipped With ABS 13. Install vacuum seal on master cylinder push rod as shown with notches on vacuum seal pointing toward master cylinder housing. Then slide vacuum seal onto master push rod until seal is seated against master cylinder housing before installing master cylinder on power brake vacuum booster. CAUTION: If vehicle is equipped with ABS, be sure old vacuum seal is removed from power brake vacuum booster before attempting to install master cylinder and NEW vacuum seal. If vacuum seal is not removed, refer to Brakes, Master Cylinder Service and Repair for required vacuum seal removal procedure. 14. Position master cylinder on studs of power brake unit, aligning push rod on power brake vacuum booster with master cylinder push rod. Master Cylinder Mounting To Vacuum Booster 15. Install the 2 master cylinder to power brake unit mounting nuts and torque to 28 Nm (250 inch lbs.). Fig 7 Type 3 Primary And Secondary Output Ports. With ABS 16. Connect brake tubes to master cylinder primary and secondary ports. Torque all tube nuts to 17 Nm (145 inch lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4052 Master Cylinder Fluid Level Sensor 17. Install the wiring harness connector on the master cylinder reservoir brake fluid level switch. 18. Bleed the base brakes and the ABS brakes hydraulic systems. Refer to Brakes Service and Repair and Antilock Brake System Service and Repair for the required procedures. 19. Road test vehicle to ensure proper operation of the base and ABS brake systems. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4053 Hydraulic Control Unit: Service and Repair Relay Box Replacement GENERAL INFORMATION The System Relay and Pump/Motor Relay are both serviced together as an assembly with the relay box. The relay box is mounted directly to the Hydraulic Control Unit (HCU). To remove the relay box from the HCU, the HCU requires removal from the vehicle. This is to allow visual access of the relay box to HCU electrical connection. Visual access to this connection is necessary to be sure connection is correctly made when installing relay box on the HCU. REMOVE 1. Disconnect negative (ground) cable from the battery and isolate the cable. 2. Remove the HCU from the vehicle. Refer to Hydraulic Control Unit Removal, for the required HCU removal procedure. Relay Box To HCU Mounting Screws 3. Unclip the 6 way wiring harness connector from the relay box. 4. Remove the 2 screws attaching the relay box assembly to the HCU. Remove only the 2 screws mounting the relay box to the HCU. Do not remove the pump motor mounting screws. Relay Box To HCU Electrical Connection 5. Grasp relay box. Without twisting or rocking, pull relay box away from pump motor housing until connector on relay box unplugs from the pump motor terminal. This is a tight connection, relay box will require a good amount of force to unplug from pump motor. 6. Remove relay box from HCU. INSTALL Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4054 Pump Motor To Relay Box Electrical Seal 1. Be sure electrical connector seal is installed in pump motor housing before installing relay box. If electrical connector seal is cracked, brittle or in any way damaged it must be replaced before installing relay box. 2. Position relay box on HCU and carefully align the terminals on the relay box with the terminals on the pump motor. 3. Grasp relay box with both hands. Then without twisting or rocking, push relay box onto the pump motor electrical connector as far as possible by hand. 4. Install and securely tighten the 2 screws attaching the relay box assembly to the HCU. 5. Reconnect the 6 way connector onto the relay box. 6. Install the HCU back in the vehicle. Refer to Hydraulic Control Unit Installation, for the required HCU installation procedure. 7. Connect the negative (-) ground cable back on the negative post of the battery. 8. Bleed the base brakes and the ABS brakes hydraulic systems. Refer to Brakes Service and Repair and Antilock Brake System Service and Repair for the required procedures. 9. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4059 39 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4060 43 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4061 45 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4062 47 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4063 51 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4064 55 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4065 57 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4066 59 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4067 63 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4068 67 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4069 69 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4070 71 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4071 173 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4072 177 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4073 179 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4074 181 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4075 187 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4076 191 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4077 193 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4078 195 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4079 201 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4080 205 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4081 207 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4082 209 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4083 256 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 4084 Wheel Speed Sensor: Specifications Front Rear Clearance Minimum Clearance 0.014 in 0.016 in Maximum Clearance 0.047 in 0.047 in Runout 0.006 in 0.006 in Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 4085 Wheel Speed Sensor: Service Precautions NOTE: Proper installation of the Wheel Speed Sensor Cables is critical to continued system operation. Be sure that cables are installed, routed and clipped properly. Failure to install speed sensor cables as in the on car service section of this manual, may result in contact with moving parts or over extension of cables, resulting in an open circuit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation Wheel Speed Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION There are four wheel speed sensors, one at each wheel. The sensors use a tone wheel to determine wheel speed. Input to the Controller Anti Lock Brake (CAB) is done on the following circuits. All of these circuits are a twisted pair. B8 and B9 for the left front wheel (cavity 8 and cavity 9). B6 and B7 for the right front wheel (cavity 6 and cavity 7). B3 and B4 for the left rear wheel (cavity 3 and cavity 4). B1 and B2 for the right rear wheel (cavity 1 and cavity 2). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 4088 Wheel Speed Sensor: Description and Operation Wheel Speed Sensors and Tone Wheels Front Wheel Speed Sensor Rear Wheel Speed Sensor With Drum Brakes Rear Wheel Speed Sensor With Rear Disc Brakes One Wheel Speed Sensor (WSS) is located at each wheel and sends a small AC signal to the Controller Antilock Brake (CAB). This signal is generated by magnetic induction created when a toothed sensor ring (tone wheel) passes the stationary magnetic Wheel Speed Sensor. The CAB converts the AC signal generated at each wheel into a digital signal. If a wheel locking tendency is detected by the CAB, it will then modulate hydraulic pressure via the Hydraulic Control Unit (HCU) to prevent the wheel(s) from locking. The front Wheel Speed Sensor is attached to a boss in the steering knuckle. The tone wheel is part of the outboard constant velocity joint. The rear Wheel Speed Sensor on rear drum brake applications is mounted to the rear brake support plate and the rear tone wheel is an integral part of the rear wheel hub and bearing assembly. The rear Wheel Speed Sensor on rear disc brake applications is mounted to the rear disc brake adapter and the rear tone wheel is also an integral part of the rearwheel hub and bearing assembly. The speed sensor air gap on both applications is NOT adjustable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 4089 The four Wheel Speed Sensors are serviced individually. The front Tone Wheels are serviced as an assembly with the outboard constant velocity joint. The rear Tone Wheels are serviced as an assembly with the rear hub and bearing assembly. Correct ABS system operation is dependent on accurate wheel speed signals. The vehicle's wheels and tires must all be the same size and type to generate accurate signals. Variations in wheel and tire size can produce inaccurate wheel speed signals. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Page 4090 Wheel Speed Sensor: Testing and Inspection CAREFUL INSPECTION Carefully inspect tone wheel at the suspected faulty wheel speed sensor for missing, chipped or broken teeth, this can cause erratic speed sensor signals. Tone wheels should show no evidence of contact with the wheel speed sensors. If contact was made, determine cause and correct before replacing the wheel speed sensor. Excessive Runout - of the tonewheel can cause erratic wheel speed sensor signals. Refer to Tone-wheel Runout under Specification. Replace drive shaft assembly or rear hub/bearing assembly if tonewheel runout exceeds the specification. Inspect For Looseness - on their mounting surfaces. Tone wheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Check the wheel speed sensor head alignment to the tone wheel. Also check the gap between the speed sensor head and the tone wheel to ensure it is at specification. See: Specifications Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front Speed Sensor Cable To Wiring Herness Connection Front Wheel Speed Sensor Attaching Bolt Front Wheel Speed Sensor Cable Routing NOTE: Proper installation of the Wheel Speed Sensor Cables is critical to continued system operation. Be sure that cables are installed, routed and clipped properly. Failure to install speed sensor cables as in the on car service section of this manual, may result in contact with moving parts or over extension of cables, resulting in an open circuit. REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. 3. Unplug speed sensor cable connector from vehicle wiring harness. Remove clip attaching speed sensor cable connector to vehicle body. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4093 4. Remove wheel speed sensor head to steering knuckle attaching bolt. 5. Carefully, remove sensor head from steering knuckle. If the sensor has seized, due to corrosion, DO NOT USE PLIERS ON SENSOR HEAD. Use a hammer and a punch and tap edge of sensor ear, rocking the sensor side to side until free. 6. Remove the speed sensor cable assembly grommets from the retaining bracket. Remove speed sensor cable routing clip from the frame of the vehicle. INSTALL 1. Connect the wheel speed sensor cable connector to the vehicle wiring harness. 2. Install the speed sensor cable assembly grommets into the retaining bracket. Install speed sensor cable routing clip onto the frame of the vehicle. 3. Install wheel speed sensor to steering knuckle attaching screw. Torque the attaching screw to 7 Nm (60 inch lbs.) 4. Install the wheel and tire assembly on vehicle. 5. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4094 Wheel Speed Sensor: Service and Repair Rear Rear Speed Sensor Connection To Vehicle Wiring Harness Speed Sensor Head Mounting And Cable Routing NOTE: Proper installation of the Wheel Speed Sensor Cables is critical to continued system operation. Be sure that cables are installed, routed and clipped properly. Failure to install speed sensor cables as in the on car service section of this manual, may result in contact with moving parts or over extension of cables, resulting in an open circuit. REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. 3. Unplug speed sensor cable connector from vehicle wiring harness. Remove clip attaching speed sensor cable connector to vehicle body. 4. Remove the speed sensor cable routing bracket from under rear brake flex hose mounting bracket. Then remove the speed sensor cable from the routing clips on the rear brake flex hose and chassis brake tube. 5. Remove bolt attaching the rear wheel speed sensor to the disc brake adapter. The remove bolt attaching speed sensor cable routing bracket to rear strut assembly. 6. Remove speed sensor head from the disc brake adapter. If the speed sensor head has seized in the adapter, DO NOT USE PLIERS ON SENSOR HEAD. INSTALL 1. Install wheel speed sensor head into disc brake adapter. 2. Install wheel speed sensor attaching bolt. Tighten the attaching bolt to a torque of 7 Nm (60 inch lbs.) 3. Install the brake flex hose and wheel speed sensor cable routing bracket on the rear strut bracket. 4. Install wheel speed sensor cable into the routing clips on the rear brake flex hose and chassis brake tube. 5. Plug speed sensor cable connector into vehicle wiring harness. Install clip attaching speed sensor cable connector to vehicle body. 6. Install the tire and wheel assembly on vehicle. 7. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures GENERAL INFORMATION The base brake system must be bled anytime air is permitted to enter the hydraulic system, due to disconnection of brake lines, hoses or components. The Antilock Brake System (ABS), particularly the Hydraulic Control Unit (HCU), should only be bled when the HCU is. replaced or removed from the vehicle, or if there is reason to believe the HCU has ingested air. Under most circumstances that would require brake bleeding, only the base brake system needs to be bled. It is important to note that excessive air in the brake system will cause a soft or spongy feeling brake pedal. During Bleeding Operations - be sure that the brake fluid level remains close to the FULL level in the reservoir. Check the fluid level periodically during the bleeding procedure and add DOT 3 brake fluid as required. The Bendix ABX-4 Brake System must be bled as two independent braking systems. The non ABS portion of the brake system is to be bled the same as any non ABS system. Refer to Brakes Service and Repair for the proper bleeding procedure to be used. This brake system can be either pressure bled or manually bled. The ABS portion of brake system MUST be bled separately. This bleeding procedure requires the use of the DRB scan tool and the bleeding sequence procedure outlined below. ABS BLEEDING PROCEDURE When bleeding the ABS system, the following bleeding sequence MUST be followed to insure complete and adequate bleeding. The ABS system can be bled using a Manual bleeding procedure or standard Pressure Bleeding Equipment. If the brake system is to be bled using pressure bleeding equipment, refer to Brakes Service and Repair. 1. Assemble and install all brake system components on vehicle making sure all hydraulic fluid lines are installed and properly torqued. ABS System Diagnostic Connector 2. Connect the DRB scan tool to the diagnostics connector. The diagnostics connector is located under the steering column cover, directly below the steering column. 3. Using the DRB scan tool, check to make sure the CAB does not have any fault codes stored. If it does, remove them using the DRB scan tool. WARNING: WHEN BLEEDING THE BRAKE SYSTEM WEAR SAFETY GLASSES. A CLEAR BLEED TUBE MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A CLEAR CONTAINER FILLED PART WAY WITH CLEAN BRAKE FLUID. DIRECT THE FLOW OF BRAKE FLUID AWAY FROM THE PAINTED SURFACES OF THE VEHICLE. BRAKE FLUID AT HIGH PRESSURE MAY COME OUT OF THE BLEEDER SCREWS WHEN OPENED. 4. Bleed the base brake system using the standard pressure or manual bleeding procedure as outlined in Brakes Service and Repair. 5. Using the DRB scan tool, go to the "Bleed ABS" routine. Apply the brake pedal firmly and initiate the "Bleed ABS" cycle one time. Release the brake pedal. 6. Bleed the base brake system again, as in step Step 4 above. 7. Repeat steps Step 5 and Step 6 above until brake fluid flows clear and free of bubbles. Check brake fluid level in reservoir periodically to prevent reservoir from running low on brake fluid. 8. Test drive the vehicle to be sure brake are operating correctly and that pedal is solid. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 4099 Brake Bleeding: Service and Repair Pressure Bleeding (Preferred Procedure) Air Trapped In Brake System Method For Purging Air From Brake System Bleeder Screw CAUTION: - Before removing the Master Cylinder cover, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder. - Use bleeder tank Special Tool C-3496-B, or equivalent with required adapter for the master cylinder reservoir to pressurize the hydraulic system for bleeding. NOTE: - For bleeding the ABS hydraulic system, refer to Hydraulic Control Unit. - Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. PROCEDURE When bleeding the brake system, some air may be trapped in the brake lines or valves far upstream, as much as ten feet from the bleeder screw. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 4100 Therefore, it is essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out. The following wheel sequence for bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulic system. ^ Left rear wheel ^ Right front wheel ^ Right rear wheel ^ Left front wheel 1. Attach a clear plastic hose to the bleeder screw starting at the right rear wheel and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. 2. Open the bleeder screw at least one full turn or more to obtain an steady stream of brake fluid. 3. After 4 to 8 ounces of fluid has been bled through the brake and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 4. Repeat the procedure at all the other remaining bleeder screws. Then check the pedal for travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to monitor the fluid level in the pressure bleeder. It must stay at the proper level so air will not be allowed to reenter the brake system through the master cylinder reservoir. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions NUMBER: 26-12-97F GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997-1998 Teves Mark IV, Teves Mark 20 ABS Diagnostic Manual - Publication Number 81-699-97012 DESCRIPTION OF CHANGES Revisions to the ABS warning light procedure Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions > Page 4105 244 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions > Page 4106 245 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > General Information Brake Warning Indicator: Description and Operation General Information Master Cylinder Fluid Level Sensor GENERAL INFORMATION The red Brake warning lamp is located in the instrument panel cluster and is used to indicate a low brake fluid condition or that the parking brake is applied. In addition, the brake warning lamp is turned on as a bulb check by the ignition switch when the ignition switch is placed in the crank position. Problems with this system will generally be of the type where the warning lamp fails to turn on when it should, or remains on when it should not. The warning lamp bulb is supplied a 12 volt ignition feed anytime the ignition switch is on. The bulb is then illuminated by completing the ground circuit either through the park brake switch, the fluid level sensor in the master cylinder reservoir, or the ignition switch in the crank position. PURPOSE The Brake Fluid Level sensor is located in the brake fluid reservoir of the master cylinder assembly. The purpose of the sensor is to provide the driver with an early warning that the brake fluid level in the master cylinder reservoir has dropped to below normal. This may indicate an abnormal loss of brake fluid in the master cylinder fluid reservoir resulting from a leak in the hydraulic system. As the fluid drops below the minimum level, the fluid level sensor closes the brake warning light circuit. This will turn on the red brake warning light. At this time, master cylinder fluid reservoir should be checked and filled to the full mark with DOT 3 brake fluid. NOTE: If brake fluid level has dropped in master cylinder fluid reservoir, the entire brake hydraulic system should he checked for evidence of a leak. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > General Information > Page 4109 Brake Warning Indicator: Description and Operation ABS Warning Lamp Circuit Operation CIRCUIT OPERATION The ABS warning lamp is an output from the Controller Anti Lock Brake (CAB) and the Antilock Brake System (ABS) relay box. It is used to alert the operator of a problem in the ABS system. The G19 circuit from the CAB and the ABS system relay is used to detect a problem. If a problem is detected, the CAB grounds the G19 circuit and illuminates the lamp in the instrument cluster. Circuit G19 is also an output of the CAB to the ABS system relay contact side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > General Information > Page 4110 Brake Warning Indicator: Description and Operation Brake Warning Lamp Circuit Operation CIRCUIT OPERATION The Brake Warning Indicator lamp is used to alert the operator of a problem with the vehicles braking system. The lamp illuminates when the ignition switch is turned to START position to perform a self check. There are two switches used in this system and they are wired in parallel form. A parking brake switch located on the parking brake mechanism will illuminate the lamp if the normally OPEN switch is CLOSED. This switch is case grounded. The other switch used is the brake warning lamp switch. This switch is normally OPEN. When the brake system pressure is below a predetermined level the switch CLOSES and completes a path to ground from the G9 circuit at the cluster, through the switch, to the left headlamp ground. If the vehicle is built for use in Canada the parking brake switch is used for the Daytime Running Lamp Module (DRL). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Testing and Inspection > Brake System Warning Lamp Test Brake Warning Indicator: Testing and Inspection Brake System Warning Lamp Test The brake warning lamp illuminates when the parking brake is applied with ignition switch turned to the ON position. The same lamp will also illuminate if one of the two service brake systems fail the when brake pedal is applied. To test the system: - As the ignition switch is turned to the start position the lamp should light. - Turn ignition switch to the ON position and apply the parking brake. The lamp should light. If lamp fails to light inspect for: - A burned out lamp - Loose, corroded or damaged socket - A damaged circuit board - A broken or disconnected wire at the switch - Defective switch Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Testing and Inspection > Brake System Warning Lamp Test > Page 4113 Brake Warning Lamp Functional Check Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Testing and Inspection > Brake System Warning Lamp Test > Page 4114 Brake Warning Indicator: Testing and Inspection Helpful Information - Check the 5 Amp fuse in cavity 11 of the fuse block. - Check the 4 Amp fuse in cavity 12 of the fuse block. - Check the Ignition Off Draw fuse in the PDC. - Check for a good ground at the instrument panel left center support. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Brake Caliper to Steering Knuckle Torque Brake Caliper to Steering Knuckle Torque Brake Caliper Bolt 31 Nm Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service Precautions > Technician Safety Information Brake Caliper: Technician Safety Information WARNING: UNDER NO CONDITION SHOULD AIR PRESSURE EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service Precautions > Technician Safety Information > Page 4121 Brake Caliper: Vehicle Damage Warnings CAUTION: - Use care when installing the caliper assembly onto the steering knuckle so the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses. - Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion and binding of piston. - Force must be applied to the piston uniformly to avoid cocking and binding of the piston in the bore of the caliper. - When inspecting caliper piston, do not use anything but solvents to clean piston surface. If surface of piston cannot be cleaned using only solvents, piston must be replaced. NOTE: - When being installed, extreme caution must be taken not to cross thread the caliper guide pin bolts. - Before vehicle is moved after any brake service work, pump the brake pedal several times to insure the vehicle has a firm brake pedal. - When using Caliper Honing Tool, Special Tool C-4095, or equivalent, coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff non-metallic rotary brush. - Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the caliper with brake fluid; wipe dry with a clean, lint free cloth and then clean a second time. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Front Caliper Brake Caliper: Description and Operation Front Caliper Exploded View Of Front Caliper Fig. 2 Piston Seal Function GENERAL INFORMATION The caliper is mounted to the steering knuckle using bushings, sleeves and 2 guide pin bolts which thread directly into bosses on the steering knuckle. Two machined abutments on the steering knuckle position the caliper. The guide pin bolts, sleeves and bushings control the side to side movement of the caliper. The piston seal is designed to pull the piston back into the bore of the caliper when the brake pedal is released. This maintains the proper brake shoe to rotor clearance. The caliper is a one piece casting with the inboard side containing a single piston cylinder bore. The front disc brake caliper piston, is manufactured from a phenolic compound. The outside diameter of the caliper piston is 54 mm. A square cut rubber piston seal is located in a machined groove in the caliper cylinder bore. This provides a hydraulic seal between the piston and the cylinder wall. A rubber dust boot is installed in the cylinder bore opening and in a groove in the piston. This prevents contamination in the bore area. As front disc brake linings wear, master cylinder reservoir brake fluid level will drop. Fluid level should be checked after replacing linings. Front disc brakes are equipped with an audible wear indicator on the outboard brake pad. This sensor omits a sound when the brake lining may need inspection and/or replacement. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Front Caliper > Page 4124 Brake Caliper: Description and Operation Rear Caliper Rear Disc Brake Assembly GENERAL INFORMATION Vehicles are equipped with a caliper assembly that has a 34 mm (1.43 in.) piston and uses a solid non-vented rotor. The caliper assembly on all applications float on rubber bushings using internal metal sleeves which are attached to the adapter using threaded guide pin bolts. The adapter and rotor shield are mounted to the rear suspension knuckles of vehicle. The adapter is used to mount the brake shoes and actuating cables for the parking brake system. The adapter also mounts the rear caliper assembly to the vehicle. The adapter has two machined abutments which are used to position and align the caliper and brake pads for movement inboard and outboard. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Page 4125 Brake Caliper: Testing and Inspection PISTON SEAL Check for brake fluid leaks in and around dust boot area and inboard brake pad, and for any ruptures, brittleness or damage to the piston dust boot. If the dust boot is damaged, or a fluid leak is visible, disassemble caliper assembly and install a new piston seal and dust boot, and piston if scored. GUIDE PIN BUSHINGS Check the guide pin dust boots to determine if they are in good condition. Replace if they are damaged, dry, or found to be brittle. Refer to Guide Pin Bushing Disassembly or Assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation Front Caliper Guide Pin Bolts Removing Caliper Assembly From Steering Knuckle Storing Brake Caliper CAUTION: During service procedures, grease or any other foreign material must be kept off caliper assembly, surfaces of braking rotor and external surfaces of hub. Handling of the braking rotor and caliper should be done in such a way as to avoid deformation of the rotor and scratching or nicking of the brake linings. During removal and installation of a wheel and tire assembly, use care not to strike the caliper. REMOVAL 1. Raise vehicle on jackstands or centered on a hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4128 2. Remove the front wheel and tire assemblies from this vehicle. 3. Remove the 2 brake caliper to steering knuckle guide pin bolts. 4. Remove caliper from steering knuckle, by first rotating free end of caliper away from steering knuckle. Then slide opposite end of caliper out from under machined abutment on steering knuckle. 5. Support the disc brake caliper firmly using a wire hanger. This is required to prevent the weight of the caliper from damaging the flexible brake hose. Installing Caliper Assembly On Steering Knuckle INSTALLATION NOTE: Step 1 below is only required when installing a caliper after new brake shoes have been installed. 1. Completely retract the caliper piston back into the bore of the caliper. 2. Lubricate both steering knuckle abutments with a liberal amount of Mopar* Multipurpose Lubricant, or equivalent. 3. If removed, install the front rotor on the hub, making sure it is squarely seated on face of hub. CAUTION: Use care when installing the caliper assembly onto the steering knuckle so the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses. 4. Carefully position brake caliper and brake shoe assemblies by hooking the end of the caliper under the edge of the steering knuckle. Then rotate caliper into position on the steering knuckle. Make sure that caliper guide pin bolts, bushings and sleeves are clear of the steering knuckle bosses. 5. Install the caliper guide pin bolts and tighten to 18 to 20 Nm (192 in. lbs.). Extreme caution should be taken not to cross thread the caliper guide pin bolts. 6. Install the wheel and tire assembly. 7. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 109 - 150 Nm (80 - 110 ft. lbs.). 8. Remove jackstands or lower hoist. Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal. 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. * Mopar is a registered trade mark of Chrysler Corporation. Rear Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4129 Caliper Assembly Guide Pin Bolts Caliper Removal/Installation Storing Caliper REMOVAL 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear wheel and tire assemblies from vehicle. 3. Remove the 2 caliper assembly to adapter guide pin bolts. 4. Remove caliper assembly from adapter and rotor by first rotating top of caliper assembly away from adapter, and then lifting caliper assembly off lower machined abutment on adapter. 5. Support caliper assembly firmly from rear strut to prevent weight of caliper from damaging the flexible brake hose. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4130 INSTALLATION NOTE: Step 1 below is only required when installing the disc brake caliper, after new brake shoes have been installed. 1. Completely retract caliper piston back into piston bore of caliper assembly. 2. Lubricate both adapter abutments with a liberal amount of Mopar* Multipurpose Lubricant, or equivalent. 3. If removed, install the rear rotor on the hub making sure it is squarely seated on the face of the hub. CAUTION: Use care when installing caliper assembly onto adapter so the guide pin bushings and sleeves do not get damaged by the mounting bosses on adapter. 4. Carefully lower caliper and brake shoe assemblies over braking disc (rotor) reversing the required removal procedure. Make sure that the caliper guide pin bolts, bushings and sleeves are clear of the adapter bosses. CAUTION: Extreme caution should be taken not to cross thread the caliper guide pin bolts when they are installed. 5. Install caliper assembly guide pin bolts into adapter and tighten. Then torque both guide pin bolts to 22 Nm (192 in. lbs.). 6. Install the wheel and tire assembly. 7. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 109 - 150 Nm (80 - 110 ft. lbs.). 8. Remove jackstands or lower hoist. Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal. 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. * Mopar is a registered trademark of Chrysler Corporation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4131 Brake Caliper: Service and Repair Disassembly and Assembly Disassembly PROCEDURE WARNING: UNDER NO CONDITION SHOULD AIR PRESSURE EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. 1. Remove caliper from brake rotor. Hang assembly on a wire hook away from rotor, so hydraulic fluid cannot get on rotor. Place a small piece of wood between the piston and caliper fingers. 2. Carefully depress brake pedal to hydraulically push piston out of bore. Then apply and hold down the brake pedal to any position beyond the first inch of pedal travel. This will prevent loss of brake fluid from the master cylinder. 3. If both front caliper pistons are to be removed, disconnect brake tube at flexible brake hose at frame rail. Plug brake tube and remove piston from opposite caliper using the same process as above for the first piston removal. 4. Disconnect the brake fluid flex hose from the caliper assembly. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion and binding of piston. 5. To disassemble caliper, mount in a vise equipped with protective jaws. 6. Remove guide pin sleeves and guide pin bushings. Refer to Guide Pin Removal. Fig. 10 Dust Boot Removal 7. Remove the piston dust boot from the caliper and discard. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4132 Removing Piston Seal From Caliper 8. Using a soft tool, such as a plastic trim stick, work piston seal out of its groove in caliper piston bore. Discard old seal. Do not use a screw driver or other metal tool for this operation, because of the possibility of scratching piston bore or burring edges of seal groove. 9. Clean all parts using alcohol or a suitable solvent and wipe dry using only a lint free cloth. No lint residue can remain in caliper bore. Clean out all drilled passages and bores. Whenever a caliper has been disassembled, a new boot and seal must be installed at assembly. Honing Brake Caliper Piston Bore 10. Inspect the piston bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. Bores that have deep scratches or scoring should be honed. Use Caliper Hone, Special Tool C-4095, or equivalent providing the diameter of the bore is not increased more than 0.0254 mm 0.001 inch.. 11. If the bore does not clean up within this specification, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. NOTE: When using Caliper Honing Tool, Special Tool C-4095, or equivalent, coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff non-metallic rotary brush. NOTE: Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the caliper with brake fluid; wipe dry with a clean, lint free cloth and then clean a second time. CAUTION: When inspecting caliper piston, do not use anything but solvents to clean piston surface. If surface of piston cannot be cleaned using only solvents, piston must be replaced. 12. Inspect caliper piston for pitting, scratches, or any physical damage. Replace piston if there is evidence of scratches, pitting or physical damage. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4133 Assembly PROCEDURE CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion and binding of piston. 1. Clamp caliper in a vise with protective caps installed on jaws of vise.. Installing New Piston Seal In Caliper 2. Dip new piston seal in clean brake fluid and install in the groove of the caliper bore. Seal should be positioned at one area in groove and gently worked around the groove, using only your fingers until properly seated. NEVER USE AN OLD PISTON SEAL. Be sure that fingers are clean and seal is not twisted or rolled. 3. Coat new piston boot with clean brake fluid leaving a generous amount inside boot. 4. Position dust boot over piston after coating with brake fluid. CAUTION: Force must be applied to the piston uniformly to avoid cocking and binding of the piston in the bore of the caliper. Installing Piston Into Caliper Bore 5. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore. 6. Position dust boot into the counterbore of the caliper assembly piston bore. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4134 7. Using a hammer and Installer Piston Caliper Boot, Special Tool C-4689 and Handle, Special Tool C-4171, or equivalent, drive boot into counterbore of the caliper. 8. Install guide pin sleeves and bushings. Refer to Guide Pin Installation. 9. Install brake pads. Refer to Disc Brake Pad Installation. 10. Before installing caliper assembly on vehicle, inspect brake rotor. If any conditions as described in Checking Brake Rotor for Runout and Thickness are present the rotor, must be replaced or refaced. If the rotor does not require any servicing, install caliper assembly. 11. Install brake hose onto caliper using banjo bolt. Torque the brake hose to caliper assembly banjo bolt to 33 Nm (24 ft. lbs). New seal washers MUST always be used when installing brake hose to caliper. 12. Bleed the brake system. Removal GENERAL INFORMATION The double pin caliper uses a sealed for life bushing and sleeve assembly If required this assembly can be serviced using the following procedure. PROCEDURE 1. Remove caliper from brake rotor. Hang caliper assembly on a wire hook away from the brake rotor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4135 Removing Inner Sleeve From Bushing 2. Push out and then pull the steel sleeve from the inside of the bushing using your fingers as shown above. Removing Bushing From Caliper 3. Using your fingers, collapse one side of the bushing. Then pull on the opposite side to remove the bushing from the brake caliper housing. Installation PROCEDURE Folded Caliper Guide Pin Bushing 1. Fold the bushing in half lengthwise at the solid middle section of the bushing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4136 Installing Caliper Guide Pin Bushing 2. Insert the folded bushing into the caliper housing. Do not use a sharp object to perform this step due to possible damage to the bushing. Bushing Correctly Installed In Caliper 3. Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the caliper housing. Flanges should be seated evenly on both sides of the bushing hole. 4. Lubricate the inside surfaces of the bushing using Mopar, Silicone Dielectric Compound or an equivalent. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4137 Fig 7 Installing Caliper Sleeves 5. Install guide pin sleeve into one end of bushing until seal area of bushing is past seal groove in sleeve. 6. Holding convoluted boot end of bushing with one hand, push steel sleeve bushing through boot until one end of bushing is fully seated into seal groove on one end of sleeve. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4138 Fig 8 Installed Caliper Bushing Sleeve 7. Holding sleeve in place, work other end of bushing over end of sleeve and into the seal grove on sleeve. Be sure other end of bushing did not come out of seal grove in sleeve. 8. When the sleeve is seated properly into the bushing, the sealed for life sleeve/bushing can be held between your fingers and easily slid back and forth without the bushing unseating from the sleeve groove. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Page 4139 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 05-10-97 > Dec > 97 > Front Brakes - Squeal or Creep/Groan Brake Pad: Customer Interest Front Brakes - Squeal or Creep/Groan NO: 05-10-97 GROUP: Brakes DATE: Dec. 19, 1997 SUBJECT: Front Brake Squeal And/Or Creep/Groan MODELS: 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES WITH 14" DISC/DRUM (SALES CODE BRA AND BRJ). SYMPTOM/CONDITION: Front brake squeal moderate brake pedal application, or creep/groan sound during zero speed creeping brake apply. DIAGNOSIS: 1. Drive the vehicle at 10 to 20 MPH, with moderate pressure apply the brakes. If a squeal sound is heard perform the Repair Procedure. 2. With the brake pedal applied, place the transmission in "drive" and slowly release the brakes until the vehicle just begins to creep. If a loud grinding, crunching, or groaning noise is heard from the front brakes, perform the Repair Procedure. PARTS REQUIRED: 1 05011069AA Pad Set, Front Disc Brake REPAIR PROCEDURE: This bulletin involves the replacement of the front brake pads. 1. Remove and replace the front brake pads following the repair procedure provided in the appropriate Neon Service Manual, Group 5. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-70-22-90 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 05-10-97 > Dec > 97 > Front Brakes - Squeal or Creep/Groan Brake Pad: All Technical Service Bulletins Front Brakes - Squeal or Creep/Groan NO: 05-10-97 GROUP: Brakes DATE: Dec. 19, 1997 SUBJECT: Front Brake Squeal And/Or Creep/Groan MODELS: 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES WITH 14" DISC/DRUM (SALES CODE BRA AND BRJ). SYMPTOM/CONDITION: Front brake squeal moderate brake pedal application, or creep/groan sound during zero speed creeping brake apply. DIAGNOSIS: 1. Drive the vehicle at 10 to 20 MPH, with moderate pressure apply the brakes. If a squeal sound is heard perform the Repair Procedure. 2. With the brake pedal applied, place the transmission in "drive" and slowly release the brakes until the vehicle just begins to creep. If a loud grinding, crunching, or groaning noise is heard from the front brakes, perform the Repair Procedure. PARTS REQUIRED: 1 05011069AA Pad Set, Front Disc Brake REPAIR PROCEDURE: This bulletin involves the replacement of the front brake pads. 1. Remove and replace the front brake pads following the repair procedure provided in the appropriate Neon Service Manual, Group 5. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-70-22-90 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Front Brake Pad: Specifications Front Brake Shoe Thickness Measurement The combined brake shoe and lining material thickness should be measured at the thinnest part of the assembly. When a set of brake shoes are worn to a total thickness of approximately 7.95 mm (5/16 inch) or less, they should be replaced. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Front > Page 4155 Brake Pad: Specifications Rear Brake Shoe Thickness Measurement The combined brake shoe and lining material thickness should be measured at the thinnest part of the assembly. When a set of brake shoes are worn to a total thickness of approximately 7.0 mm (9/32 inch), they should be replaced. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service Precautions > Technician Safety Information Brake Pad: Technician Safety Information WARNING: ALTHOUGH FACTORY INSTALLED BRAKE LININGS ARE MADE FROM ASBESTOS FREE MATERIALS, SOME AFTER MARKET BRAKE LININGS MAY CONTAIN ASBESTOS. THIS SHOULD BE TAKEN INTO ACCOUNT WHEN SERVICING A VEHICLE'S BRAKE SYSTEM, WHEN AFTERMARKET BRAKE LININGS MAY HAVE BEEN INSTALLED ON THE VEHICLE. ALWAYS WEAR A RESPIRATOR WHEN CLEANING BRAKE COMPONENTS AS ASBESTOS CAN CAUSE SERIOUS BODILY HARM SUCH AS ASBESTOSIS AND OR CANCER. NEVER CLEAN BRAKE COMPONENTS BY USING COMPRESSED AIR, USE ONLY A VACUUM CLEANER SPECIFICALLY DESIGNED FOR THE REMOVAL OF BRAKE DUST. IF A VACUUM CLEANER IS NOT AVAILABLE, CLEAN BRAKE PARTS USING ONLY WATER DAMPENED SHOP TOWELS. DO NOT CREATE BRAKE LINING DUST BY SANDING BRAKE LININGS WHEN SERVICING A VEHICLE. DISPOSE OF ALL DUST AND DIRT SUSPECTED OF CONTAINING ASBESTOS FIBERS USING ONLY SEALED AIR TIGHT BAGS OR CONTAINERS. FOLLOW ALL RECOMMENDED SAFETY PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA), FOR HANDLING AND DISPOSAL OF PRODUCTS CONTAINING ASBESTOS. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service Precautions > Technician Safety Information > Page 4158 Brake Pad: Vehicle Damage Warnings CAUTION: Use care when installing caliper assembly onto adapter, so the guide pin bushings and sleeves do not get damaged by the mounting bosses on adapter. CAUTION: Extreme caution should be taken not to cross thread the caliper guide pin bolts when they are installed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front Removal WARNING: ALTHOUGH FACTORY INSTALLED BRAKE LININGS ARE MADE FROM ASBESTOS FREE MATERIALS, SOME AFTER MARKET BRAKE LININGS MAY CONTAIN ASBESTOS. THIS SHOULD BE TAKEN INTO ACCOUNT WHEN SERVICING A VEHICLE'S BRAKE SYSTEM, WHEN AFTERMARKET BRAKE LININGS MAY HAVE BEEN INSTALLED ON THE VEHICLE. ALWAYS WEAR A RESPIRATOR WHEN CLEANING BRAKE COMPONENTS AS ASBESTOS CAN CAUSE SERIOUS BODILY HARM SUCH AS ASBESTOSIS AND OR CANCER. NEVER CLEAN BRAKE COMPONENTS BY USING COMPRESSED AIR, USE ONLY A VACUUM CLEANER SPECIFICALLY DESIGNED FOR THE REMOVAL OF BRAKE DUST. IF A VACUUM CLEANER IS NOT AVAILABLE, CLEAN BRAKE PARTS USING ONLY WATER DAMPENED SHOP TOWELS. DO NOT CREATE BRAKE LINING DUST BY SANDING BRAKE LININGS WHEN SERVICING A VEHICLE. DISPOSE OF ALL DUST AND DIRT SUSPECTED OF CONTAINING ASBESTOS FIBERS USING ONLY SEALED AIR TIGHT BAGS OR CONTAINERS. FOLLOW ALL RECOMMENDED SAFETY PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA), FOR HANDLING AND DISPOSAL OF PRODUCTS CONTAINING ASBESTOS. GENERAL INFORMATION During service procedures, grease or any other foreign material must be kept off caliper assembly, surfaces of braking rotor and external surfaces of hub. Handling of the braking rotor and caliper should be done in such a way as to avoid deformation of the rotor and scratching or nicking of the brake linings. If inspection reveals that the square sectioned caliper piston seal is worn or damaged, it should be replaced immediately. During removal and installation of a wheel and tire assembly, use care not to strike the caliper. NOTE: Before vehicle is moved after any brake service work, pump the brake pedal several times to insure the vehicle has a firm brake pedal. PROCEDURE 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies from vehicle. 3. Remove the 2 caliper to steering knuckle guide pin bolts. 4. Remove caliper from steering knuckle, by first rotating free end of caliper away from steering knuckle. Then slide opposite end of caliper out from under machined abutment on steering knuckle. Storing Brake Caliper 5. Support caliper firmly to prevent weight of caliper from damaging the flexible brake hose. 6. Remove front brake rotor from hub by pulling it straight off wheel mounting studs. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4161 Removing Outboard Brake Pad 7. Remove outboard brake pad by prying the pad retaining clip over raised area on caliper. Then slide the pad down and off the caliper. Removing Inboard Brake Pad From Piston 8. Pull inboard brake pad away from piston until retaining clip is free from cavity in piston. CALIPER INSPECTION Check caliper for piston seal leaks (brake fluid in and around boot area and inboard lining) and for any ruptures of the piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper and install a new seal and boot, (and piston if scored). Refer to Disc Brake Caliper Service and Repair. Check the caliper dust boot and caliper pin bushings to determine if they are in good condition. Replace if they are damaged, dry, or found to be brittle. Refer to Disc Brake Caliper Service and Repair. Installation WARNING: ALTHOUGH FACTORY INSTALLED BRAKE LININGS ARE MADE FROM ASBESTOS FREE MATERIALS, SOME AFTER MARKET BRAKE LININGS MAY CONTAIN ASBESTOS. THIS SHOULD BE TAKEN INTO ACCOUNT WHEN SERVICING A VEHICLE'S BRAKE SYSTEM, WHEN AFTERMARKET BRAKE LININGS MAY HAVE BEEN INSTALLED ON THE VEHICLE. ALWAYS WEAR A RESPIRATOR WHEN CLEANING BRAKE COMPONENTS AS ASBESTOS CAN CAUSE SERIOUS BODILY HARM SUCH AS ASBESTOSIS AND OR CANCER. NEVER CLEAN BRAKE COMPONENTS BY USING COMPRESSED AIR, USE ONLY A VACUUM CLEANER SPECIFICALLY DESIGNED FOR THE REMOVAL OF BRAKE DUST. IF A VACUUM CLEANER IS NOT AVAILABLE, CLEAN BRAKE PARTS USING ONLY WATER DAMPENED SHOP TOWELS. DO NOT CREATE BRAKE LINING DUST BY SANDING BRAKE LININGS WHEN SERVICING A VEHICLE. DISPOSE OF ALL DUST AND DIRT SUSPECTED OF CONTAINING ASBESTOS FIBERS USING ONLY SEALED AIR TIGHT BAGS OR CONTAINERS. FOLLOW ALL RECOMMENDED SAFETY PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA), FOR HANDLING AND DISPOSAL OF PRODUCTS CONTAINING ASBESTOS. NOTE: Before vehicle is moved after any brake service work, pump the brake pedal several times to insure the vehicle has a firm brake pedal. CALIPER INSPECTION Check caliper for piston seal leaks (brake fluid in and around boot area and inboard lining) and for any ruptures of the piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper and install a new seal and boot, (and piston if scored). Refer to Disc Brake Caliper Service Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4162 and Repair. Check the caliper dust boot and caliper pin bushings to determine if they are in good condition. Replace if they are damaged, dry, or found to be brittle. Refer to Disc Brake Caliper Service and Repair. PROCEDURE 1. Completely retract caliper piston back into piston bore of caliper assembly. This is required for caliper installation with new brake shoe assemblies. 2. Lubricate both steering knuckle abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent. 3. Install the front rotor on the hub, making sure it is squarely seated on face of hub. 4. Remove the protective paper from the noise suppression gasket on both the inner and outer brake shoe assemblies (if equipped). Front Brake Shoe Assembly Identification NOTE: The inboard and outboard brake shoes are not common. Inboard Brake Shoe 5. Install the new inboard brake shoe assembly into the caliper piston by firmly pressing into piston bore with thumbs. Be sure inboard brake shoe assembly is positioned squarely against face of caliper piston. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4163 Installing Outboard Brake Shoe 6. Slide the new outboard brake shoe assembly onto the caliper assembly. CAUTION: Use care when installing the caliper assembly onto the steering knuckle so the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses. 7. Carefully position brake caliper and brake shoe assemblies over brake rotor by hooking end of caliper under the steering knuckle. Then rotate caliper into position on steering knuckle. Make sure that caliper guide pin bolts, bushings and sleeves are clear of the steering knuckle bosses. 8. Install the caliper guide pin bolts and tighten to 18 to 20 Nm (192 in. lbs.). Extreme caution should be taken not to cross thread the caliper guide pin bolts. 9. Install the wheel and tire assembly. 10. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 109 - 150 Nm (80 - 110 ft. lbs.). 11. Remove jackstands or lower hoist. Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal. 12. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. Cleaning and Inspection LINING WEAR If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the wheel and tire assemblies, and the calipers. Remove the front disc brake shoes. Refer to Disc Brake Pad Rear Removal. Material Thickness The combined brake shoe and lining material thickness should be measured at the thinnest part of the assembly. When a set of brake shoes are worn to a total thickness of approximately 7.95 mm (5/16 inch) they should be replaced. Replace both brake shoe assemblies (inboard and outboard). It is necessary that both front wheel sets be replaced whenever brake shoe assemblies on either side are replaced. If Replacement Is Not Required If the brake shoe assemblies do not require replacement, reinstall, the assemblies making sure each brake shoe is returned to the original position. Refer to Disc Brake Pad Front Installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4164 Brake Pad: Service and Repair Rear Removal WARNING: ALTHOUGH FACTORY INSTALLED BRAKE LININGS ARE MADE FROM ASBESTOS FREE MATERIALS, SOME AFTER MARKET BRAKE LININGS MAY CONTAIN ASBESTOS. THIS SHOULD BE TAKEN INTO ACCOUNT WHEN SERVICING A VEHICLE'S BRAKE SYSTEM, WHEN AFTERMARKET BRAKE LININGS MAY HAVE BEEN INSTALLED ON THE VEHICLE. ALWAYS WEAR A RESPIRATOR WHEN CLEANING BRAKE COMPONENTS AS ASBESTOS CAN CAUSE SERIOUS BODILY HARM SUCH AS ASBESTOSIS AND OR CANCER. NEVER CLEAN BRAKE COMPONENTS BY USING COMPRESSED AIR, USE ONLY A VACUUM CLEANER SPECIFICALLY DESIGNED FOR THE REMOVAL OF BRAKE DUST. IF A VACUUM CLEANER IS NOT AVAILABLE, CLEAN BRAKE PARTS USING ONLY WATER DAMPENED SHOP TOWELS. DO NOT CREATE BRAKE LINING DUST BY SANDING BRAKE LININGS WHEN SERVICING A VEHICLE. DISPOSE OF ALL DUST AND DIRT SUSPECTED OF CONTAINING ASBESTOS FIBERS USING ONLY SEALED AIR TIGHT BAGS OR CONTAINERS. FOLLOW ALL RECOMMENDED SAFETY PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA), FOR HANDLING AND DISPOSAL OF PRODUCTS CONTAINING ASBESTOS. GENERAL INFORMATION During service procedures, grease or any other foreign material must be kept off caliper assembly, surfaces of braking rotor and external surfaces of hub. Handling of the braking rotor and caliper should be done in such a way as to avoid deformation of the rotor and scratching or nicking of the brake linings.If inspection reveals that the square sectioned caliper piston seal is worn or damaged, it should be replaced immediately. During removal and installation of a wheel and tire assembly, use care not to strike the caliper. NOTE: Before vehicle is moved after any brake service work, pump the brake pedal several times to insure the vehicle has a firm brake pedal. PROCEDURE 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear wheel and tire assemblies from vehicle. 3. Remove the 2 caliper assembly to adapter guide pin bolts. 4. Remove caliper assembly from adapter and rotor by first rotating top of caliper assembly away from adapter, and then lifting caliper assembly off lower machined abutment on adapter. Storing Caliper 5. Support caliper assembly firmly from rear strut to prevent weight of caliper from damaging the flexible brake hose. 6. Remove rear rotor from hub/bearing assembly. Then inspect drum-in-hat parking brake shoes and parking brake braking surface on rotor for any signs of excessive wear or damage. Replace parking brake shoes if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4165 Removing/Installing Outboard Brake Shoe 7. Remove outboard brake pad from caliper by prying brake pad retaining clip over raised area on caliper. Then slide brake pad down and off the caliper. Removing Inboard Brake Pad 8. Pull inboard brake pad away from caliper piston, until retaining clip is free from cavity in piston. CALIPER INSPECTION Check caliper for piston seal leaks (brake fluid in and around boot area and inboard lining) and for any ruptures of the piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper and install a new seal and boot, (and piston if scored). Refer to Disc Brake Caliper Service and Repair. Check the caliper dust boot and caliper pin bushings to determine if they are in good condition. Replace if they are damaged, dry, or found to be brittle. Refer to Disc Brake Caliper Service and Repair. Installation WARNING: ALTHOUGH FACTORY INSTALLED BRAKE LININGS ARE MADE FROM ASBESTOS FREE MATERIALS, SOME AFTER MARKET BRAKE LININGS MAY CONTAIN ASBESTOS. THIS SHOULD BE TAKEN INTO ACCOUNT WHEN SERVICING A VEHICLE'S BRAKE SYSTEM, WHEN AFTERMARKET BRAKE LININGS MAY HAVE BEEN INSTALLED ON THE VEHICLE. ALWAYS WEAR A RESPIRATOR WHEN CLEANING BRAKE COMPONENTS AS ASBESTOS CAN CAUSE SERIOUS BODILY HARM SUCH AS ASBESTOSIS AND OR CANCER. NEVER CLEAN BRAKE COMPONENTS BY USING COMPRESSED AIR, USE ONLY A VACUUM CLEANER SPECIFICALLY DESIGNED FOR THE REMOVAL OF BRAKE DUST. IF A VACUUM CLEANER IS NOT AVAILABLE, CLEAN BRAKE PARTS USING ONLY WATER DAMPENED SHOP TOWELS. DO NOT CREATE BRAKE LINING DUST BY SANDING BRAKE LININGS WHEN SERVICING A VEHICLE. DISPOSE OF ALL DUST AND DIRT SUSPECTED OF CONTAINING ASBESTOS FIBERS USING ONLY SEALED AIR TIGHT BAGS OR CONTAINERS. FOLLOW ALL RECOMMENDED SAFETY PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4166 ENVIRONMENTAL PROTECTION AGENCY (EPA), FOR HANDLING AND DISPOSAL OF PRODUCTS CONTAINING ASBESTOS. NOTE: Before vehicle is moved after any brake service work, pump the brake pedal several times to insure the vehicle has a firm brake pedal. CALIPER INSPECTION Check caliper for piston seal leaks (brake fluid in and around boot area and inboard lining) and for any ruptures of the piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper and install a new seal and boot, (and piston if scored). Refer to Disc Brake Caliper Service and Repair. Check the caliper dust boot and caliper pin bushings to determine if they are in good condition. Replace if they are damaged, dry, or found to be brittle. Refer to Disc Brake Caliper Service and Repair. PROCEDURE 1. Completely retract the caliper piston back into the piston bore of the caliper assembly. This is required for caliper installation when new brake pad assemblies are installed on caliper. 2. Lubricate both adapter abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent. 3. Install rear rotor on the hub making sure it is squarely seated on face of hub. 4. Remove protective paper from noise suppression gasket on both inner and outer brake pad assemblies (if equipped). 5. Install new inboard brake shoe assembly into caliper piston by firmly pressing into piston bore with thumbs. Be sure inboard brake shoe assembly is positioned squarely against face of caliper piston. 6. Slide new outboard brake pad assembly onto the caliper assembly. Be sure retaining clip is squarely seated in the depressed areas on the caliper. CAUTION: Use care when installing caliper assembly onto adapter, so the guide pin bushings and sleeves do not get damaged by the mounting bosses on adapter. 7. Carefully lower caliper and brake shoe assemblies over braking disc (rotor) reversing the required removal procedure. Make sure that caliper guide pin bolts, bushings and sleeves are clear of the adapter bosses. CAUTION: Extreme caution should be taken not to cross thread the caliper guide pin bolts when they are installed. 8. Install caliper assembly guide pin bolts into adapter and tighten. Then torque both guide pin bolts to 22 Nm (192 in. lbs.). 9. Install the wheel and tire assembly. 10. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 109 - 150 Nm (80 - 110 ft. lbs.). 11. Remove jackstands or lower hoist. Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal. 12. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. Cleaning and Inspection Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4167 LINING WEAR If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the wheel and tire assemblies, and the calipers. Remove the rear disc brake shoes. Refer to Disc Brake Pad Rear Removal. Material Thickness The combined brake shoe and lining material thickness should be measured at the thinnest part of the assembly. When a set of brake shoes are worn to a total thickness of approximately 7.0 mm (9/32 inch) they should be replaced. Replace both brake shoe assemblies (inboard and outboard). It is necessary that both rear wheel sets be replaced whenever brake shoe assemblies on either side are replaced. If Replacement Is Not Required If the brake shoe assemblies do not require replacement, reinstall, the assemblies making sure each brake shoe is returned to the original position. Refer to Disc Brake Pad Rear Installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Rotor Specifications Rotor Specifications BRAKE ROTOR Front Rear ROTOR TYPE Vented Solid ROTOR THICKNESS 19.87 - 20.13 mm (0.782 - 0.793 in.) 8.75 - 9.25 mm (0.344 - 0.364 in.) MINIMUM ROTOR THICKNESS 18.4 mm (0.724 in.) 7.25 mm (0.285 in.) Brake rotor minimum thickness is cast/stamped on the outer surface of the rotor hub. This marking includes 0.76 mm (0.030 in.) allowable rotor wear beyond the recommended 0.76 mm (0.030 in.) of rotor refacing. ROTOR THICKNESS VARIATION 0.013 mm (0.0005 in.) 0.013 mm (0.0005 in.) ROTOR RUNOUT * 0.13 mm (0.005 in.) 0.13 mm (0.005 in.) * TIR - Total Indicator Reading (measured on vehicle) ROTOR MICRO-FINISH 15 - 80 RMS 15 - 80 RMS Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4171 Brake Rotor/Disc: Service Precautions NOTE: - Any servicing of the rotor requires extreme care to maintain the rotor to within service tolerances to ensure proper brake action. - All rotors have markings for minimum allowable thickness cast on an un-machined surface of the rotor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4172 Brake Rotor/Disc: Testing and Inspection Checking Rotor For Runout Indexing Rotor And Hub Checking Hub For Runout GENERAL INFORMATION Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action. Before refinishing or refacing a rotor, the disc should be checked and inspected for the following conditions: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4173 ^ Braking surface scoring, rust, impregnation of lining material and worn ridges. ^ Excessive lateral runout or wobble. ^ Thickness variation (Parallelism). ^ Dishing or distortion (Flatness). If a vehicle has not been driven for a period of time, the rotor surface will rust in the area not covered by the brake lining and cause noise and chatter when the brakes are applied. Excessive wear and scoring of the rotor can cause temporary improper lining contact if ridges are not removed before installation of new brake pad assemblies. Some discoloration or wear of the rotor surface is normal and does not require resurfacing when linings are replaced. Excessive runout or wobble in a rotor can increase pedal travel due to piston knock back. This will increase guide pin sleeve wear due to tendency of caliper to follow rotor wobble. Thickness variation in a rotor can also result in pedal pulsation, chatter and surge due to variation in brake output. This can also be caused by excessive runout in rotor or hub. Dishing or distortion can be caused by extreme heat and abuse of the brakes. RUNOUT On vehicle rotor runout is the combination of the individual runout of the hub face and the runout of the rotor. (The hub and rotor runouts are separable). To measure runout on the vehicle, remove the wheel and reinstall the lug nuts tightening the rotor to the hub. Mount Dial Indicator, Special Tool C-3339 with Mounting Adapter, Special Tool SP-1910, or equivalents on steering arm. Dial indicator plunger should contact braking surface of rotor approximately one inch from edge of rotor. Check lateral runout (both sides of rotor) runout should not exceed 0.13 mm (0.005 inch). If runout is in excess of the specification, check the lateral runout of the hub face. Before removing rotor from hub, make a chalk mark across both the rotor and one wheel stud on the high side of runout so you'll know exactly how the rotor and hub was originally mounted. Remove rotor from hub. Install Dial Indicator, Special Tool C-3339 and Mounting Adapter, Special Tool SP- 1910, or equivalents on steering knuckle. Position stem so it contacts hub face near outer diameter. Care must be taken to position stem outside the stud circle but inside the chamfer on the hub rim. Clean hub surface before checking. Runout should not exceed 0.08 mm (0.003 inch). If runout exceeds this specification, hub must be replaced. Refer to Steering and Suspension. If hub runout does not exceed this specification, install rotor on hub with chalk marks two wheel studs apart. Tighten nuts in the proper sequence and torque to specifications. Finally, check runout of rotor to see if runout is now within specifications. If runout is not within specifications, install a new rotor or reface rotor, being careful to remove as little as possible from each side of rotor. Remove equal amounts from each side of rotor. Do not reduce thickness below minimum thickness cast into the unmachined surface of the rotor. Checking Rotor For Thickness Variation THICKNESS VARIATION Thickness variation measurements of rotor should be made in conjunction with runout. Measure thickness of rotor at 12 equal points with a micrometer at a radius approximately 25 mm (1 inch) from edge of rotor. If thickness measurements vary by more than 0.013 mm (0.0005 inch) rotor should be removed and resurfaced, or a new rotor installed. If cracks or burned spots are evident, rotor must be replaced. Light scoring and/or wear is acceptable. If heavy scoring or warping is evident, the rotor must be machined or replaced. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4174 Brake Rotor/Disc: Service and Repair Fig 6 Refacing Brake Disc Fig 7 Refacing Brake Disc -- Final Finish Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4175 Front Rotor Thickness Markings NOTE: All rotors have markings for minimum allowable thickness cast on an un-machined surface of the rotor. NOTE: Any servicing of the rotor requires extreme care to maintain the rotor to within service tolerances to ensure proper brake action. MACHINING PROCEDURES If the rotor surface is deeply scored or warped, or there is a complaint of brake roughness or pulsation, the rotor should be resurfaced, refaced or replaced. The previous image shows the location of measurements and specifications when servicing the rotor. This marking includes 0.76 mm (0.030 inch) allowable rotor wear beyond the recommended 0.76 mm (0.030 inch) of rotor refacing. The collets, shafts and adapters used on the brake lathe and the bearing cups in the rotor MUST be clean and free from any chips or contamination. When mounting the rotor on the brake lathe, strict attention to the brake lathe manufacturer's operating instructions is required. If the rotor is not mounted properly, the lateral runout will be worse after refacing or resurfacing than before. REFACING BRAKE ROTOR Refacing of the rotor is not required each time the brake pads are replaced.When refacing a rotor the required 0.8 mm (0.003 inch) Total Indicator Reading (TIR) and 0.013 mm (0.0005 inch) thickness variation limits MUST BE MAINTAINED. Extreme care in the operation of rotor turning equipment is required. The use of a double straddle cutter that machines both sides of the rotor at the same time is highly recommended. RESURFACING BRAKE ROTOR This operation can be used when rotor surface is rusty, has lining deposits or excessive lateral runout or thickness variation is evident. A sanding rotor attachment will remove surface contamination without removing much rotor material. It will generally follow variations in thickness that are in the rotor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Customer Interest for Backing Plate: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Customer Interest for Backing Plate: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 4185 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Backing Plate: > 05-01-98 > Jan > 98 > Rear Brakes Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Backing Plate: > 05-01-98 > Jan > 98 > Rear Brakes Howl During Low Speed Stop > Page 4191 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Page 4192 Backing Plate: Specifications Support Plate To Knuckle Casting Attaching Bolts .................................................................................................................................. 75 Nm (55 ft. lbs.) Tube Nut To Wheel Cylinder Fitting .................................................................................................................................................... 17 Nm (145 in. lbs.). Hub And Bearing Assembly Retaining Nut .......................................................................................................................................... 217 Nm (160 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Removal Backing Plate: Service and Repair Removal PROCEDURE 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear tire and wheel assembly from vehicle. Rear Hub And Bearing Dust Cap 3. Remove bearing dust cap from the rear hub and bearing assembly. 4. Remove the rear hub and bearing assembly retaining nut. Then remove the rear hub and bearing assembly from spindle. 5. Remove rear brake shoe assemblies from the brake support plate. Refer to Rear Brake Shoes Service and Repair Removal. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Removal > Page 4195 6. Disconnect rear brake flex hose tube from wheel cylinder. 7. Remove park brake actuator lever from the park brake cable. 8. Position a 1/2 wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable housing out of support plate. Remove wrench when retainer is free from the park brake cable mounting hole in the rear brake support plate. Alternate method is to use a aircraft type hose clamp over cable housing end fitting compressing the three fingers. 9. Remove the 4 brake support plate to knuckle attaching bolt and washer assemblies. Separate brake support plate from rear suspension knuckle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Removal > Page 4196 Backing Plate: Service and Repair Installation PROCEDURE 1. Install brake support plate and gasket on rear suspension knuckle casting. Torque support plate to knuckle casting attaching bolts to 75 Nm (55 ft. lbs.). 2. Insert parking brake cable end fitting into brake support plate. 3. Hand start hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.). 4. Attach parking brake cable to the parking brake actuator. 5. Install rear brake shoe assemblies on the brake support plate. Refer to Rear Brake Shoes Service and Repair installation. 6. Install rear hub and bearing assembly on rear spindle. Install a NEW hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install dust cap. 7. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 8. Install brake drum. Adjust and bleed service brakes. 9. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 10. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 109 - 150 Nm (80 - 110 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications Rear Drum Specifications Nominal Diameter ................................................................................................................................ ............................................................. 7.875" Maximum Machine Limit ...................................................................................................................... ............................................................ 7.904" Discard Diameter ................................................................................................................................. .............................................................. 7.921" Runout Limit ........................................................................................................................................ ............................................................. 0.006" Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 4200 Brake Drum: Service and Repair Brake Drum And Hub And Bearing Assembly REMOVE Further clearance can be obtained by backing off the brake automatic adjuster screw. Remove rubber plug from top of brake support plate. Rotate automatic adjuster screw assembly with an upward motion, using a medium size screwdriver. 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove the rear wheel and tire assemblies from the vehicle. 3. Remove rear brake drum to hub retaining clips (if equipped). 4. Remove rear brake drum from rear hub/bearing assembly. 5. Inspect brake linings for wear, shoe alignment and contamination. Maximum Brake Drum Diameter Identification Measure drum runout and diameter. If not to specification, reface drum. (Runout should not exceed 0.1524 mm or 0.006 inch). The diameter variation (oval shape) of the drum braking surface must not exceed either 0.0635 mm (0.0025 inch) in 30° or 0.0889 mm (0.0035 inch) in 360°. All brake drums are marked with the maximum allowable brake drum diameter. INSTALL 1. Install rear brake drum assembly on rear hub and bearing assembly. 2. Install the wheel and tire assembly. 3. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 109 - 150 Nm (80 - 110 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal Brake Shoe: Service and Repair Removal PROCEDURE 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove the rear wheel and tire assemblies from the vehicle. Rear Brake Drum Assembly 3. Remove rear brake drum to hub retaining clips (if equipped). Then remove rear brake drum from hub and bearing assembly. Automatic Adjustment Lever Spring 4. Remove adjustment lever to brake shoe spring. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal > Page 4205 5. Remove automatic adjustment lever. 6. Remove both brake shoe assembly to brake support plate hold down clips and pins. 7. Remove lower brake shoe to anchor plate return spring. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal > Page 4206 8. Remove the park brake lever pin to rear brake shoe retaining clip. Remove/Install Brake Shoes 9. Remove front and rear brake shoe assemblies, upper return spring and automatic adjuster screw from brake support plate as an assembly. CLEANING AND INSPECTION Clean metal portion of brake shoes. Check to see if shoes are bent. Lining should show contact across entire width and from heel to toe, otherwise replace. Shoes with lack of contact at toe or heel may be improperly ground. Clean and inspect support and adjusting screws. Apply a thin coat of Mopar Multi-Purpose Lubricant or equivalent to the threads of the self adjuster. Replace adjusting screw if corroded. If old springs have overheated or are damaged, replace. Overheating indications are paint discoloration or distorted end coils. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal > Page 4207 Brake Shoe: Service and Repair Installation CLEANING AND INSPECTION Clean metal portion of brake shoes. Check to see if shoes are bent. Lining should show contact across entire width and from heel to toe, otherwise replace. Shoes with lack of contact at toe or heel may be improperly ground. Clean and inspect support and adjusting screws. Apply a thin coat of Mopar Multi-Purpose Lubricant or equivalent to the threads of the self adjuster. Replace adjusting screw if corroded. If old springs have overheated or are damaged, replace. Overheating indications are paint discoloration or distorted end coils. PROCEDURE 1. Lubricate the eight shoe contact areas on the support plate and anchor using Mopar Multi-Purpose Lubricant or equivalent. 2. Assemble front and rear brake shoe assembly, automatic adjuster screw and upper return spring before installation on brake support plate. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal > Page 4208 Remove/Install Brake Shoes 3. Install the pre-assembled brake shoes, automatic adjuster screw and upper return spring on the brake support plate. 4. Install the wave washer on the pin of park brake lever. 5. Install pin on park brake lever into hole in rear brake shoe assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal > Page 4209 6. Install both brake shoe, to brake support plate, hold down pins and clips. 7. Install the lower brake shoe to anchor plate return spring. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal > Page 4210 8. Install the automatic adjustment lever, on the front brake shoe of the rear wheel brake assembly. Automatic Adjustment Lever Spring 9. Install the automatic adjustment lever to front brake shoe assembly spring. 10. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 11. Install the rear brake drums on the hubs. 12. Adjust rear brake shoes. 13. Install the wheel and tire assembly. 14. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 109 - 150 Nm (80 - 110 ft. lbs.). 15. Road test vehicle. The automatic adjuster will continue the brake adjustment during the road test of the vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder 115 in.lb Tube Nut 145 in.lb Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Page 4214 Rear Wheel Cylinder (Exploded View) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Page 4215 Wheel Cylinder: Service Precautions NOTE: When installing wheel cylinder on brake support plate, be sure it is positioned squarely (horizontal) to the brake shoe assemblies. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. 3. Remove rear brake drum. 4. Remove rear brake shoe assemblies from the brake support plate. Refer to Brake Shoe Service and Repair Removal. 5. If brake shoes are wet with grease or brake fluid, remove and replace. 6. Disconnect the rear brake flex hose from the wheel cylinder. 7. Remove rear wheel cylinder attaching bolts. 8. Remove rear wheel cylinder assembly from brake support plate. INSTALL 1. Apply a small bead of silicone sealer around the mating surface of the wheel cylinder to brake support plate. NOTE: When installing wheel cylinder on brake support plate, be sure it is positioned squarely (horizontal) to the brake shoe assemblies. 2. Install wheel cylinder onto brake support plate. Tighten the attaching bolts to 13 Nm (115 in. lbs.). 3. Hand start hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to 17 Nm (145 in. lbs.). 4. Install rear brake shoe assemblies on the brake support plate. Refer to Brake Shoe Service and Repair Installation. 5. Install rear brake drum onto rear hub. 6. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 109 - 150 Nm (80 - 110 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4218 7. Adjust the rear brakes. 8. Bleed the entire brake system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4219 Wheel Cylinder: Service and Repair Cleaning and Inspection With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. Visually check the boots for cuts, tears, or heat cracks. If any of these conditions exist, the wheel cylinders should be completely cleaned, inspected and new parts installed. If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid, the brake shoes must be replaced. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4220 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul Fig 3 Wheel Cylinder DISASSEMBLE To disassemble the wheel cylinders, proceed as follows: 1. Pry boots away from cylinders and remove. 2. Press IN on one piston to force out opposite piston, cup and spring. Then using a soft tool such as a dowel rod, press out the cup and piston that remain in the wheel cylinder. 3. Wash wheel cylinder, pistons, and spring in clean brake fluid or alcohol; DO NOT USE ANY PETROLEUM BASE SOLVENTS. clean thoroughly and blow dry with compressed air. Inspect cylinder bore and piston for scoring and pitting. Do not use a rag as lint from the rag will stick to bore surfaces.. 4. Wheel cylinder bores and pistons that are badly scored or pitted should be replaced. Cylinder walls that have light scratches, or show signs of corrosion, can usually be cleaned with crocus cloth, using a circular motion. Black stains on the cylinder walls are caused by piston cups and will not impair operation of cylinder. ASSEMBLE Before assembling the pistons and new cups in the wheel cylinders, dip them in clean brake fluid. If the boots are deteriorated, cracked or do not fit tightly on the pistons or the cylinder casting, install new boots. 1. Coat cylinder bore with clean brake fluid. 2. Lightly coat the sealing lip and outer surfaces of the wheel cylinder cups with Mopar Protect-A-Cup Lubricant. 3. Install expansion spring with cup expanders in cylinder. Install cups in each end of cylinder with open end of cups facing each other. 4. Install piston in each end of cylinder having the flat face of each piston contacting the flat face of each cup, already installed. 5. Coat the interior surfaces of the push on boots with the Mopar Protect-A-Cup Lubricant 6. Install a boot over each end of cylinder. Be careful not to damage boot during installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures GENERAL INFORMATION The base brake system must be bled anytime air is permitted to enter the hydraulic system, due to disconnection of brake lines, hoses or components. The Antilock Brake System (ABS), particularly the Hydraulic Control Unit (HCU), should only be bled when the HCU is. replaced or removed from the vehicle, or if there is reason to believe the HCU has ingested air. Under most circumstances that would require brake bleeding, only the base brake system needs to be bled. It is important to note that excessive air in the brake system will cause a soft or spongy feeling brake pedal. During Bleeding Operations - be sure that the brake fluid level remains close to the FULL level in the reservoir. Check the fluid level periodically during the bleeding procedure and add DOT 3 brake fluid as required. The Bendix ABX-4 Brake System must be bled as two independent braking systems. The non ABS portion of the brake system is to be bled the same as any non ABS system. Refer to Brakes Service and Repair for the proper bleeding procedure to be used. This brake system can be either pressure bled or manually bled. The ABS portion of brake system MUST be bled separately. This bleeding procedure requires the use of the DRB scan tool and the bleeding sequence procedure outlined below. ABS BLEEDING PROCEDURE When bleeding the ABS system, the following bleeding sequence MUST be followed to insure complete and adequate bleeding. The ABS system can be bled using a Manual bleeding procedure or standard Pressure Bleeding Equipment. If the brake system is to be bled using pressure bleeding equipment, refer to Brakes Service and Repair. 1. Assemble and install all brake system components on vehicle making sure all hydraulic fluid lines are installed and properly torqued. ABS System Diagnostic Connector 2. Connect the DRB scan tool to the diagnostics connector. The diagnostics connector is located under the steering column cover, directly below the steering column. 3. Using the DRB scan tool, check to make sure the CAB does not have any fault codes stored. If it does, remove them using the DRB scan tool. WARNING: WHEN BLEEDING THE BRAKE SYSTEM WEAR SAFETY GLASSES. A CLEAR BLEED TUBE MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A CLEAR CONTAINER FILLED PART WAY WITH CLEAN BRAKE FLUID. DIRECT THE FLOW OF BRAKE FLUID AWAY FROM THE PAINTED SURFACES OF THE VEHICLE. BRAKE FLUID AT HIGH PRESSURE MAY COME OUT OF THE BLEEDER SCREWS WHEN OPENED. 4. Bleed the base brake system using the standard pressure or manual bleeding procedure as outlined in Brakes Service and Repair. 5. Using the DRB scan tool, go to the "Bleed ABS" routine. Apply the brake pedal firmly and initiate the "Bleed ABS" cycle one time. Release the brake pedal. 6. Bleed the base brake system again, as in step Step 4 above. 7. Repeat steps Step 5 and Step 6 above until brake fluid flows clear and free of bubbles. Check brake fluid level in reservoir periodically to prevent reservoir from running low on brake fluid. 8. Test drive the vehicle to be sure brake are operating correctly and that pedal is solid. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 4226 Brake Bleeding: Service and Repair Pressure Bleeding (Preferred Procedure) Air Trapped In Brake System Method For Purging Air From Brake System Bleeder Screw CAUTION: - Before removing the Master Cylinder cover, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder. - Use bleeder tank Special Tool C-3496-B, or equivalent with required adapter for the master cylinder reservoir to pressurize the hydraulic system for bleeding. NOTE: - For bleeding the ABS hydraulic system, refer to Hydraulic Control Unit. - Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. PROCEDURE When bleeding the brake system, some air may be trapped in the brake lines or valves far upstream, as much as ten feet from the bleeder screw. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 4227 Therefore, it is essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out. The following wheel sequence for bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulic system. ^ Left rear wheel ^ Right front wheel ^ Right rear wheel ^ Left front wheel 1. Attach a clear plastic hose to the bleeder screw starting at the right rear wheel and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. 2. Open the bleeder screw at least one full turn or more to obtain an steady stream of brake fluid. 3. After 4 to 8 ounces of fluid has been bled through the brake and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 4. Repeat the procedure at all the other remaining bleeder screws. Then check the pedal for travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to monitor the fluid level in the pressure bleeder. It must stay at the proper level so air will not be allowed to reenter the brake system through the master cylinder reservoir. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Brake Caliper to Steering Knuckle Torque Brake Caliper to Steering Knuckle Torque Brake Caliper Bolt 31 Nm Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service Precautions > Technician Safety Information Brake Caliper: Technician Safety Information WARNING: UNDER NO CONDITION SHOULD AIR PRESSURE EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service Precautions > Technician Safety Information > Page 4233 Brake Caliper: Vehicle Damage Warnings CAUTION: - Use care when installing the caliper assembly onto the steering knuckle so the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses. - Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion and binding of piston. - Force must be applied to the piston uniformly to avoid cocking and binding of the piston in the bore of the caliper. - When inspecting caliper piston, do not use anything but solvents to clean piston surface. If surface of piston cannot be cleaned using only solvents, piston must be replaced. NOTE: - When being installed, extreme caution must be taken not to cross thread the caliper guide pin bolts. - Before vehicle is moved after any brake service work, pump the brake pedal several times to insure the vehicle has a firm brake pedal. - When using Caliper Honing Tool, Special Tool C-4095, or equivalent, coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff non-metallic rotary brush. - Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the caliper with brake fluid; wipe dry with a clean, lint free cloth and then clean a second time. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Front Caliper Brake Caliper: Description and Operation Front Caliper Exploded View Of Front Caliper Fig. 2 Piston Seal Function GENERAL INFORMATION The caliper is mounted to the steering knuckle using bushings, sleeves and 2 guide pin bolts which thread directly into bosses on the steering knuckle. Two machined abutments on the steering knuckle position the caliper. The guide pin bolts, sleeves and bushings control the side to side movement of the caliper. The piston seal is designed to pull the piston back into the bore of the caliper when the brake pedal is released. This maintains the proper brake shoe to rotor clearance. The caliper is a one piece casting with the inboard side containing a single piston cylinder bore. The front disc brake caliper piston, is manufactured from a phenolic compound. The outside diameter of the caliper piston is 54 mm. A square cut rubber piston seal is located in a machined groove in the caliper cylinder bore. This provides a hydraulic seal between the piston and the cylinder wall. A rubber dust boot is installed in the cylinder bore opening and in a groove in the piston. This prevents contamination in the bore area. As front disc brake linings wear, master cylinder reservoir brake fluid level will drop. Fluid level should be checked after replacing linings. Front disc brakes are equipped with an audible wear indicator on the outboard brake pad. This sensor omits a sound when the brake lining may need inspection and/or replacement. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Front Caliper > Page 4236 Brake Caliper: Description and Operation Rear Caliper Rear Disc Brake Assembly GENERAL INFORMATION Vehicles are equipped with a caliper assembly that has a 34 mm (1.43 in.) piston and uses a solid non-vented rotor. The caliper assembly on all applications float on rubber bushings using internal metal sleeves which are attached to the adapter using threaded guide pin bolts. The adapter and rotor shield are mounted to the rear suspension knuckles of vehicle. The adapter is used to mount the brake shoes and actuating cables for the parking brake system. The adapter also mounts the rear caliper assembly to the vehicle. The adapter has two machined abutments which are used to position and align the caliper and brake pads for movement inboard and outboard. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Page 4237 Brake Caliper: Testing and Inspection PISTON SEAL Check for brake fluid leaks in and around dust boot area and inboard brake pad, and for any ruptures, brittleness or damage to the piston dust boot. If the dust boot is damaged, or a fluid leak is visible, disassemble caliper assembly and install a new piston seal and dust boot, and piston if scored. GUIDE PIN BUSHINGS Check the guide pin dust boots to determine if they are in good condition. Replace if they are damaged, dry, or found to be brittle. Refer to Guide Pin Bushing Disassembly or Assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation Front Caliper Guide Pin Bolts Removing Caliper Assembly From Steering Knuckle Storing Brake Caliper CAUTION: During service procedures, grease or any other foreign material must be kept off caliper assembly, surfaces of braking rotor and external surfaces of hub. Handling of the braking rotor and caliper should be done in such a way as to avoid deformation of the rotor and scratching or nicking of the brake linings. During removal and installation of a wheel and tire assembly, use care not to strike the caliper. REMOVAL 1. Raise vehicle on jackstands or centered on a hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4240 2. Remove the front wheel and tire assemblies from this vehicle. 3. Remove the 2 brake caliper to steering knuckle guide pin bolts. 4. Remove caliper from steering knuckle, by first rotating free end of caliper away from steering knuckle. Then slide opposite end of caliper out from under machined abutment on steering knuckle. 5. Support the disc brake caliper firmly using a wire hanger. This is required to prevent the weight of the caliper from damaging the flexible brake hose. Installing Caliper Assembly On Steering Knuckle INSTALLATION NOTE: Step 1 below is only required when installing a caliper after new brake shoes have been installed. 1. Completely retract the caliper piston back into the bore of the caliper. 2. Lubricate both steering knuckle abutments with a liberal amount of Mopar* Multipurpose Lubricant, or equivalent. 3. If removed, install the front rotor on the hub, making sure it is squarely seated on face of hub. CAUTION: Use care when installing the caliper assembly onto the steering knuckle so the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses. 4. Carefully position brake caliper and brake shoe assemblies by hooking the end of the caliper under the edge of the steering knuckle. Then rotate caliper into position on the steering knuckle. Make sure that caliper guide pin bolts, bushings and sleeves are clear of the steering knuckle bosses. 5. Install the caliper guide pin bolts and tighten to 18 to 20 Nm (192 in. lbs.). Extreme caution should be taken not to cross thread the caliper guide pin bolts. 6. Install the wheel and tire assembly. 7. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 109 - 150 Nm (80 - 110 ft. lbs.). 8. Remove jackstands or lower hoist. Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal. 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. * Mopar is a registered trade mark of Chrysler Corporation. Rear Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4241 Caliper Assembly Guide Pin Bolts Caliper Removal/Installation Storing Caliper REMOVAL 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear wheel and tire assemblies from vehicle. 3. Remove the 2 caliper assembly to adapter guide pin bolts. 4. Remove caliper assembly from adapter and rotor by first rotating top of caliper assembly away from adapter, and then lifting caliper assembly off lower machined abutment on adapter. 5. Support caliper assembly firmly from rear strut to prevent weight of caliper from damaging the flexible brake hose. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4242 INSTALLATION NOTE: Step 1 below is only required when installing the disc brake caliper, after new brake shoes have been installed. 1. Completely retract caliper piston back into piston bore of caliper assembly. 2. Lubricate both adapter abutments with a liberal amount of Mopar* Multipurpose Lubricant, or equivalent. 3. If removed, install the rear rotor on the hub making sure it is squarely seated on the face of the hub. CAUTION: Use care when installing caliper assembly onto adapter so the guide pin bushings and sleeves do not get damaged by the mounting bosses on adapter. 4. Carefully lower caliper and brake shoe assemblies over braking disc (rotor) reversing the required removal procedure. Make sure that the caliper guide pin bolts, bushings and sleeves are clear of the adapter bosses. CAUTION: Extreme caution should be taken not to cross thread the caliper guide pin bolts when they are installed. 5. Install caliper assembly guide pin bolts into adapter and tighten. Then torque both guide pin bolts to 22 Nm (192 in. lbs.). 6. Install the wheel and tire assembly. 7. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 109 - 150 Nm (80 - 110 ft. lbs.). 8. Remove jackstands or lower hoist. Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal. 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. * Mopar is a registered trademark of Chrysler Corporation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4243 Brake Caliper: Service and Repair Disassembly and Assembly Disassembly PROCEDURE WARNING: UNDER NO CONDITION SHOULD AIR PRESSURE EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. 1. Remove caliper from brake rotor. Hang assembly on a wire hook away from rotor, so hydraulic fluid cannot get on rotor. Place a small piece of wood between the piston and caliper fingers. 2. Carefully depress brake pedal to hydraulically push piston out of bore. Then apply and hold down the brake pedal to any position beyond the first inch of pedal travel. This will prevent loss of brake fluid from the master cylinder. 3. If both front caliper pistons are to be removed, disconnect brake tube at flexible brake hose at frame rail. Plug brake tube and remove piston from opposite caliper using the same process as above for the first piston removal. 4. Disconnect the brake fluid flex hose from the caliper assembly. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion and binding of piston. 5. To disassemble caliper, mount in a vise equipped with protective jaws. 6. Remove guide pin sleeves and guide pin bushings. Refer to Guide Pin Removal. Fig. 10 Dust Boot Removal 7. Remove the piston dust boot from the caliper and discard. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4244 Removing Piston Seal From Caliper 8. Using a soft tool, such as a plastic trim stick, work piston seal out of its groove in caliper piston bore. Discard old seal. Do not use a screw driver or other metal tool for this operation, because of the possibility of scratching piston bore or burring edges of seal groove. 9. Clean all parts using alcohol or a suitable solvent and wipe dry using only a lint free cloth. No lint residue can remain in caliper bore. Clean out all drilled passages and bores. Whenever a caliper has been disassembled, a new boot and seal must be installed at assembly. Honing Brake Caliper Piston Bore 10. Inspect the piston bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. Bores that have deep scratches or scoring should be honed. Use Caliper Hone, Special Tool C-4095, or equivalent providing the diameter of the bore is not increased more than 0.0254 mm 0.001 inch.. 11. If the bore does not clean up within this specification, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. NOTE: When using Caliper Honing Tool, Special Tool C-4095, or equivalent, coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff non-metallic rotary brush. NOTE: Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the caliper with brake fluid; wipe dry with a clean, lint free cloth and then clean a second time. CAUTION: When inspecting caliper piston, do not use anything but solvents to clean piston surface. If surface of piston cannot be cleaned using only solvents, piston must be replaced. 12. Inspect caliper piston for pitting, scratches, or any physical damage. Replace piston if there is evidence of scratches, pitting or physical damage. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4245 Assembly PROCEDURE CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion and binding of piston. 1. Clamp caliper in a vise with protective caps installed on jaws of vise.. Installing New Piston Seal In Caliper 2. Dip new piston seal in clean brake fluid and install in the groove of the caliper bore. Seal should be positioned at one area in groove and gently worked around the groove, using only your fingers until properly seated. NEVER USE AN OLD PISTON SEAL. Be sure that fingers are clean and seal is not twisted or rolled. 3. Coat new piston boot with clean brake fluid leaving a generous amount inside boot. 4. Position dust boot over piston after coating with brake fluid. CAUTION: Force must be applied to the piston uniformly to avoid cocking and binding of the piston in the bore of the caliper. Installing Piston Into Caliper Bore 5. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore. 6. Position dust boot into the counterbore of the caliper assembly piston bore. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4246 7. Using a hammer and Installer Piston Caliper Boot, Special Tool C-4689 and Handle, Special Tool C-4171, or equivalent, drive boot into counterbore of the caliper. 8. Install guide pin sleeves and bushings. Refer to Guide Pin Installation. 9. Install brake pads. Refer to Disc Brake Pad Installation. 10. Before installing caliper assembly on vehicle, inspect brake rotor. If any conditions as described in Checking Brake Rotor for Runout and Thickness are present the rotor, must be replaced or refaced. If the rotor does not require any servicing, install caliper assembly. 11. Install brake hose onto caliper using banjo bolt. Torque the brake hose to caliper assembly banjo bolt to 33 Nm (24 ft. lbs). New seal washers MUST always be used when installing brake hose to caliper. 12. Bleed the brake system. Removal GENERAL INFORMATION The double pin caliper uses a sealed for life bushing and sleeve assembly If required this assembly can be serviced using the following procedure. PROCEDURE 1. Remove caliper from brake rotor. Hang caliper assembly on a wire hook away from the brake rotor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4247 Removing Inner Sleeve From Bushing 2. Push out and then pull the steel sleeve from the inside of the bushing using your fingers as shown above. Removing Bushing From Caliper 3. Using your fingers, collapse one side of the bushing. Then pull on the opposite side to remove the bushing from the brake caliper housing. Installation PROCEDURE Folded Caliper Guide Pin Bushing 1. Fold the bushing in half lengthwise at the solid middle section of the bushing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4248 Installing Caliper Guide Pin Bushing 2. Insert the folded bushing into the caliper housing. Do not use a sharp object to perform this step due to possible damage to the bushing. Bushing Correctly Installed In Caliper 3. Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the caliper housing. Flanges should be seated evenly on both sides of the bushing hole. 4. Lubricate the inside surfaces of the bushing using Mopar, Silicone Dielectric Compound or an equivalent. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4249 Fig 7 Installing Caliper Sleeves 5. Install guide pin sleeve into one end of bushing until seal area of bushing is past seal groove in sleeve. 6. Holding convoluted boot end of bushing with one hand, push steel sleeve bushing through boot until one end of bushing is fully seated into seal groove on one end of sleeve. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4250 Fig 8 Installed Caliper Bushing Sleeve 7. Holding sleeve in place, work other end of bushing over end of sleeve and into the seal grove on sleeve. Be sure other end of bushing did not come out of seal grove in sleeve. 8. When the sleeve is seated properly into the bushing, the sealed for life sleeve/bushing can be held between your fingers and easily slid back and forth without the bushing unseating from the sleeve groove. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Page 4251 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4255 Brake Fluid: Service Precautions CAUTION: Use only Mopar brake fluid or an equivalent from a tightly sealed container. Brake fluid must conform to DOT 3 specifications. Do not use petroleum-based fluid because seal damage in the brake system will result. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4256 Brake Fluid: Testing and Inspection CAUTION: The hydraulic fluid used in automotive brake systems is hygroscopic. This means that the hydraulic fluid tends to absorb moisture from the atmosphere over periods of time. As hydraulic brake fluid absorbs moisture, it effects the function of the vehicles hydraulic brake system. For this reason, the vehicle's hydraulic brake fluid should be drained and replaced using fresh clean hydraulic brake fluid every two years. When replacing hydraulic brake fluid, use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications. BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber parts or components containing rubber coming into contact with the brake fluid. This includes the master cylinder, proportioning valves, caliper seals, wheel cylinder seals, ABS hydraulic control unit (HCU), and all hydraulic fluid hoses. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4257 Brake Fluid: Service and Repair Master Cylinder Fluid Level CAUTION:Use only Mopar brake fluid or an equivalent from a tightly sealed container. Brake fluid must conform to DOT 3 specifications. Do not use petroleum-based fluid because seal damage in the brake system will result. Check master cylinder reservoir brake fluid level a minimum of twice a year. Master cylinder reservoirs are marked with the words FULL AND MIN indicating proper range of the master cylinder fluid level. If necessary, add specified brake fluid bringing level to the FULL mark on the side of the master cylinder brake fluid reservoir. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Switch <--> [Brake Fluid Level Sensor/Switch] > Component Information > Locations Master Cylinder Fluid Level Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Switch <--> [Brake Fluid Level Sensor/Switch] > Component Information > Locations > Page 4261 Brake Fluid Level Switch: Service and Repair GENERAL INFORMATION The master cylinder or brake fluid reservoir does not have to be removed from vehicle for replacement of the brake fluid level sensor. Master Cylinder Fluid Level Sensor 1. Remove wiring harness connector from brake fluid reservoir level sensor. Brake Fluid Level Switch Retaining Tabs 2. Compress retaining tabs on end of brake fluid level switch. Removing/Installing Fluid Reservoir Level Switch 3. While compressing retaining tabs, grasp opposite end of brake fluid level switch and pull it out of master cylinder brake fluid reservoir. 4. Correctly align the replacement level switch with its mounting hole in the brake fluid reservoir. Push switch into fluid reservoir until retaining tabs are fully expanded on opposite side of fluid reservoir. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Switch <--> [Brake Fluid Level Sensor/Switch] > Component Information > Locations > Page 4262 5. Install the wiring harness connector onto the brake fluid level switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation Brake Hose/Line: Description and Operation The purpose of the chassis brake tubes and flex hoses is to transfer the pressurized brake fluid developed by the master cylinder to the wheel brakes of the vehicle. The chassis tubes are steel with a corrosion resistant coating applied to the external surfaces and the flex hoses are made of reinforced rubber. The rubber flex hoses allow for the movement of the vehicle's suspension. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Testing and Inspection > Brake Hoses Brake Hose/Line: Testing and Inspection Brake Hoses Flexible rubber hose is used at both front and rear brakes. Inspection of brake hoses should be performed whenever the brake system is serviced and every 7,500 miles or 12 months, whichever comes first (every engine oil change). Inspect hydraulic brake hoses for severe surface cracking, scuffing, worn spots or physical damage. If the fabric casing of the rubber hose becomes exposed due to cracks or abrasions in the rubber hose cover, the hose should be replaced immediately. Eventual deterioration of the hose can take place with possible burst failure. Faulty installation can cause twisting, resulting in wheel, tire, or chassis interference. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Testing and Inspection > Brake Hoses > Page 4268 Brake Hose/Line: Testing and Inspection Brake Lines The steel brake tubing should be inspected periodically for evidence of corrosion, physical damage or contact with moving or hot components of the vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Line Replacement Brake Hose/Line: Service and Repair Brake Line Replacement GENERAL INFORMATION Always use Mopar replacement brake hose assemblies to ensure quality, correct length and superior fatigue life. Care should be taken to make sure. that the tube and hose mating surfaces are clean and free from nicks and burrs. Hose assemblies for each brake are unique and not interchangeable.Use new copper seal washers on all connections using Banjo Bolts and tighten all fittings to their specified torques. PROCEDURE The flexible front hydraulic brake hose should always be installed on the vehicle by first attaching the Banjo connector to the caliper assembly. Then bolt the intermediate hose bracket to the strut assembly allowing the bracket to position the hose to prevent twisting. Attach the hose to brake tubing, before attaching to front frame rail. Then tighten all brake line fittings to specified torque. On vehicles equipped with rear drum brakes, install rear brake hoses first to wheel cylinders and rear struts and then attach hose bracket to body. On vehicles equipped with rear disc brakes, attach brake hoses to calipers and struts first and then attach brake hose bracket to body. Following this procedure will reduce potential for twisting brake during installation procedure. Only double wall 4.75 mm (3/16 in.) steel brake line tubing, with Al- Rich/ZN-AL alloy coating should be used for replacement. Care must be taken when replacing brake tubing, to be sure the proper bending and flaring tools and procedures are used to avoid kinking. Do not route the tubes against sharp edges, moving components or into hot areas. All tubes should be properly attached with recommended retaining clips. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Line Replacement > Page 4271 Brake Hose/Line: Service and Repair Brake Tubing Repair/Tube Flaring Tube End Properly Prepared For Flaring Double Inverted Brake Tube Flare NOTE: Place tube nut on tubing before flaring the tubing. GENERAL INFORMATION Only double wall 4.75 mm (3/16 in.) steel tubing with Al-rich/ZN-AL alloy coating and the correct tube nuts are to be used for replacement of a hydraulic brake tube. Care should be taken when repairing brake tubing, to be sure the proper bending and flaring tools and procedures are used, to avoid kinking. Do not route the tubes against sharp edges, moving components or into hot areas. All tubes should be properly attached with recommended retaining clips. Using Tubing Cutter, Special Tool C-3478-A or equivalent, cut off damaged seat or tubing. Ream out any burrs or rough edges showing on inside of tubing. This will make the ends of tubing square and ensure better seating of flared end tubing. DOUBLE INVERTED TUBING FLARES To make a double inverted tubing flare. Open handles of Flaring Tool, Special Tool C-4047 or equivalent. Then rotate jaws of tool until the mating jaws of tubing size are centered between vertical posts on tool. Slowly close handles with tubing inserted in jaws but do not apply heavy pressure to handle as this will lock tubing in place. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Line Replacement > Page 4272 Place gauge (Form A) on edge over end of brake tubing. Push tubing through jaws until end of tubing contacts the recessed notch in gauge matching the tubing size. Squeeze handles of flaring tool and lock tubing in place. Place 3/16 inch plug of gauge (A) down in end of tubing. Swing compression disc over gauge and center tapered flaring screw in recess of disc. Screw in until plug gauge has seated on jaws of flaring tool. This action has started to invert the extended end of the tubing. Remove gauge and continue to screw down until tool is firmly seated in tubing. Remove tubing from flaring tool and inspect seat. Refer to tube routing diagrams for proper brake tube routing and clip locations. Replace any damaged tube routing clips. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Line Replacement > Page 4273 Brake Hose/Line: Service and Repair Brake Tubing/Hose Replacement GENERAL INFORMATION Always use Mopar replacement brake hose assemblies to ensure quality, correct length and superior fatigue life. Care should be taken to make sure. that the tube and hose mating surfaces are clean and free from nicks and burrs. Hose assemblies for each brake are unique and not interchangeable.Use new copper seal washers on all connections using Banjo Bolts and tighten all fittings to their specified torques. PROCEDURE The flexible front hydraulic brake hose should always be installed on the vehicle by first attaching the Banjo connector to the caliper assembly. Then bolt the intermediate hose bracket to the strut assembly allowing the bracket to position the hose to prevent twisting. Attach the hose to brake tubing, before attaching to front frame rail. Then tighten all brake line fittings to specified torque. On vehicles equipped with rear drum brakes, install rear brake hoses first to wheel cylinders and rear struts and then attach hose bracket to body. On vehicles equipped with rear disc brakes, attach brake hoses to calipers and struts first and then attach brake hose bracket to body. Following this procedure will reduce potential for twisting brake during installation procedure. Only double wall 4.75 mm (3/16 in.) steel brake line tubing, with Al- Rich/ZN-AL alloy coating should be used for replacement. Care must be taken when replacing brake tubing, to be sure the proper bending and flaring tools and procedures are used to avoid kinking. Do not route the tubes against sharp edges, moving components or into hot areas. All tubes should be properly attached with recommended retaining clips. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Page 4274 Cutting And Flaring Of Brake Fluid Tubing Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Proportioning Valve - Pressure Adapter Tool Revision Brake Proportioning/Combination Valve: Technical Service Bulletins Proportioning Valve - Pressure Adapter Tool Revision NUMBER: 05-03-00 GROUP: Brakes DATE: April 14, 2000 SUBJECT: Proportioning Valve Brake Pressure Adapter Tool Revision MODELS: 1995-1999 (PL) Neon DISCUSSION: Figure 1 Diagnosing and testing the brake proportioning valves following the procedure in the appropriate Neon Service Manual calls for the use of the Brake Pressure Adapter Set 6805 and Brake Gauge Set C-4007-A. Alternate adapters from prior tool shipments should now be used on the Neon in place of the adapters provided in the Brake Pressure Adapter Set 6805. When the Neon Service Manual calls for Adapter 6805-3, use Adapter 8187-2 (Figure 1) which was shipped with the 1998 Concorde/Intrepid special tools in kit 8180CC or stored on panel 78. When the Neon Service Manual calls for Adapter 6805-4, use Adapter 6833-1 (Figure 1) which was shipped in the 1996 Minivan special tool kit and stored on panel 70. If you are unable to locate these adapters (6833-1 & 8187-2), they are available separately through Miller Special Tools (1-800-801-5420). POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > With Antilock Brakes Brake Proportioning/Combination Valve: Specifications With Antilock Brakes Proportioning Valve ............................................................................................................................. .................................................... 40 Nm (30 ft. lbs.) Tube Nut ........................................................... ..................................................................................................................................... 17 Nm (145 in. lbs.) Split Point ..................................................................................................................................... .............................................................................. 400 psi Slope ........................................................ .............................................................................................................................................................. ......... 0.34 Inlet Pressure .................................................................................................................... ........................................................................................ 1000 psi Outlet Pressure ............................ .............................................................................................................................................................. .......... 550-650 psi Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > With Antilock Brakes > Page 4281 Brake Proportioning/Combination Valve: Specifications Without Antilock Brakes Brake Line Tube Nuts At The Proportioning Valve .............................................................................................................................. 17 Nm (145 in. lbs.) Split Point ..................................................................................................................................... .............................................................................. 400 psi Slope: Disc/Drum ............................................................................................................................................ ................................................................. 0.43 Disc/Disc .................................................................... ........................................................................................................................................... 0.34 Inlet Pressure ...................................................................................................................................... ...................................................................... 1000 psi Outlet Pressure: Disc/Drum ............................................................................................................................................ ..................................................... 600-700 psi Disc/Disc .................................................................... ............................................................................................................................... 550-650 psi Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 4282 Brake Proportioning/Combination Valve: Service Precautions CAUTION: - Be sure the pressure test fitting being installed into the Hydraulic Control Unit (HCU) has the correct thread sizes for installation into the HCU and installation of the proportioning valve. - Be sure the pressure test fitting being installed into proportioning valve, has the correct thread sizes for installation into the proportioning valve and installation of brake tube fitting into proportioning valve. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 4283 Brake Proportioning/Combination Valve: Application and ID Fig 35 Type 3 Proportioning Valve Identification Fig 35 Type 3 Proportioning Valve Identification SALES CODE, BRAKE SYSTEM TYPE AND IDENTIFICATION BRA (14" Disc/Drum): Black Band BRB (14" Disc/Disc): Bar Code Label Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 4284 Brake Proportioning/Combination Valve: Description and Operation Fig 35 Type 3 Proportioning Valve Identification Master Cylinder For ABS Equipped Vehicles Fig 4 Type 3 Master Cylinder. Less ABS GENERAL INFORMATION This vehicle uses screw-in proportioning valves at the Master Cylinder or Hydraulic Control Unit (HCU) instead of the combination valve used in prior designs. With this new design, the chassis brake tubes connect directly from the master cylinder or HCU to the brake flex hose. The non-ABS master cylinders are a four outlet design with two screw-in proportioning valves attached directly to the inboard side of the master cylinder housing. The ABS Master Cylinders are a two outlet design with the screw-in proportioning valves attached directly to the HCU. PURPOSE Proportioning valves balance front to rear braking by controlling at a given ratio, the increase in rear brake system hydraulic pressure above a preset level (split point). Under light pedal application, the proportioning valve allows full hydraulic pressure to be applied to the rear brakes. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 4285 IDENTIFICATION There are two proportioning valve assemblies used in each vehicle. Due to differences in thread sizes, each proportioning valve has a different part number. During any service procedures identify valve assemblies by supplier part number and or the color identification band. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > Proportioning Valve Testing Brake Proportioning/Combination Valve: Testing and Inspection Proportioning Valve Testing With Antilock Brakes Proportioning Valve Location On Hydraulic Control Unit Proportioning Valve Installation For Pressure Testing Pressure Gauges Installed On Pressure Test Fittings At Hydraulic Control Unit PROCEDURE 1. Road test vehicle to verify premature rear wheel Antilock Brake System (ABS) cycling, to determine which proportioning valve needs to be tested. 2. Remove hydraulic brake tube from one of the proportioning valves. 3. Then remove proportioning valve from that outlet port of the Hydraulic Control Unit HCU. CAUTION: Be sure the pressure test fitting being installed into the HCU, has the correct thread sizes for installation into the HCU and Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > Proportioning Valve Testing > Page 4288 installation of the proportioning valve. 4. Install Pressure Test Fitting, Special Tool 6805-1 or 6805-2, or equivalents into the outlet port of the HCU. 5. Install proportioning valve into pressure test fitting installed in the HCU outlet port. CAUTION: Be sure the pressure test fitting being installed into proportioning valve, has the correct thread sizes for installation into the proportioning valve and installation of brake tube fitting into proportioning valve. 6. Install Pressure Test Fitting, Special Tool 6805-3 or 6805-4, or equivalents into the outlet of the proportioning valve. 7. Connect brake tube onto pressure test fitting installed in proportioning valve. 8. Install a Pressure Gauge, Special Tool C-4007-A, or equivalent into each pressure test fitting. Bleed air out of hose from pressure test fitting to pressure gauge, at pressure gauge to remove all trapped air. 9. With the aid of a helper, apply pressure to the brake pedal until reading on proportioning valve inlet gauge, is at the pressure shown on the following chart. Then check the pressure reading on the proportioning valve outlet gauge. If proportioning valve outlet pressure does not agree with value shown on the following chart, when inlet pressure shown on chart is obtained, replace the proportioning valve. If proportioning valve is within pressure specifications do not replace proportioning valve. 10. Install proportioning valve in HCU and hand tighten until proportioning is fully installed and 0-ring seal is seated into HCU. Then torque proportioning valve to 40 Nm (30 ft. lbs.). 11. Install brake tube on proportioning valve. Torque tube nut to 17 Nm (145 in. lbs.). 12. Bleed the affected brake line. See Bleeding Brake System in the Service Adjustments section of the manual for proper bleeding procedure. 13. Repeat steps 2 through 12 for the second proportioning valve. 14. Check rear wheel brake shoe linings for contamination or for replacement brake shoes not meeting OEM brake lining material specifications. These conditions can also be a possible cause for a premature rear wheel skid. Without Antilock Brakes Non ABS Proportioning Valve Location Proportioning Valve Installation For Pressure Testing Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > Proportioning Valve Testing > Page 4289 Pressure Gauges Installed On Pressure Test Fittings TESTING 1. After road testing vehicle to determine which rear wheel exhibits premature rear wheel skid, to determine which proportioning valve needs to be tested. 2. Remove hydraulic brake line from proportioning valve controlling the rear wheel of the vehicle which has premature wheel skid. 3. Then remove the proportioning valve from the rear brake line. CAUTION: Be sure the pressure test fitting being installed into proportioning valve, has the correct thread sizes for installation into the proportioning valve and installation of brake tube fitting. 4. Install Pressure Test Fitting, Special Tool 6805-1 or 6805-2, or equivalents on rear brake tube which the proportioning valve was removed from. 5. Install proportioning valve into pressure test fitting installed on rear brake tube. CAUTION: Be sure the pressure test fitting being installed into proportioning valve, has the correct thread sizes for installation into the proportioning valve and installation of brake tube fitting. 6. Install Pressure Test Fitting, Special Tool 6805-3 or 6805-4, or equivalents into outlet of the proportioning valve. 7. Connect brake hydraulic line onto pressure test fitting installed in proportioning valve 8. Install a Pressure Gauge, Special Tool C-400 7-A, or equivalent into each pressure test fitting. Bleed air out of hose from pressure test fitting to pressure gauge, at pressure gauge to remove all trapped air. hose. 9. With the aid of a helper, apply pressure to the brake pedal until reading on proportioning valve inlet gauge, is at the pressure shown on the following chart. Then check the pressure reading on the proportioning valve outlet gauge. If proportioning valve outlet pressure does not agree with value shown on the following chart, when inlet pressure shown on chart is obtained, replace the proportioning valve. If proportioning valve is within pressure specifications do not replace proportioning valve. 10. Check rear wheel brake shoe linings for contamination or for replacement brake shoes not meeting OEM brake lining material specifications. These conditions can also be a possible cause for a premature rear wheel skid. 11. Install proportioning valve in rear brake line and hand tighten both tube nuts until they are fully seated in proportioning valve. 12. Tighten both brake line tube nuts at the proportioning valve to a torque of 17 Nm (145 in-lbs.). 13. Bleed the affected brake line. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > Proportioning Valve Testing > Page 4290 Brake Proportioning/Combination Valve: Testing and Inspection With ABS Proportioning Valve Location On Hydraulic Control Unit TESTING If premature rear wheel ABS cycling occurs on a hard brake application, it could be an indication that a malfunction has occurred with one of the proportioning valves. One proportioning valve controls the right rear brake, and the other proportioning valve controls the left rear brake. Since ABS cycles both rear brakes together, both valves must be tested to isolate the suspect proportioning valve. The test procedure is the same for both rear wheel proportioning valves. The pressure test fittings used for each proportioning valve though are different due to proportioning valve and brake tube nut thread sizes being unique for each rear wheel. Refer to procedures for testing the required proportioning valve. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > Proportioning Valve Testing > Page 4291 Brake Proportioning/Combination Valve: Testing and Inspection Without ABS Non ABS Proportioning Valve Location Proportioning Valve Installation For Pressure Testing Pressure Gauges Installed On Pressure Test Fittings CAUSES If premature rear wheel skid occurs on a hard brake application, it could be an indication that a malfunction has occurred with one of the rear brake proportioning valves. TESTING One proportioning valve controls the right rear brake, and the other proportioning valve controls the left rear brake. Therefore, a road test to determine which rear brake slides first is essential. Once the wheel which slides first is determined, refer to procedures to diagnose the proportioning valve. The test procedure for a premature rear wheel skid is the same for both rear wheel proportioning valves. The pressure test Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > Proportioning Valve Testing > Page 4292 fittings used for each proportioning valve though are different due to proportioning valve and brake tube nut thread sizes being unique for each rear wheel. After road testing vehicle to determine which wheel skids first, the proper test fittings required will have to be determined. Then refer to procedures for testing the required proportioning valve. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > With Antilock Brakes Brake Proportioning/Combination Valve: Service and Repair With Antilock Brakes Rear Wheel Proportioning Valve Location On HCU GENERAL INFORMATION The HCU does not require removal from the vehicle for the replacement of the proportioning valves. Use the proportioning valve test procedure under Testing and Inspection to determine which proportioning valve requires replacement, then replace it using procedure below. REMOVE 1. Disconnect the brake tube fitting from the proportioning valve requiring removal from the HCU. 2. Remove proportioning valve requiring replacement, from the HCU. INSTALL 1. Wet O-ring seal on new proportioning valve using clean fresh brake fluid. 2. Install proportioning valve in HCU and hand tighten until proportioning is fully installed and 0-ring seal is seated into HCU. Then torque proportioning valve to 40 Nm (30 ft. lbs.). 3. Install brake tube on proportioning valve. Tighten tube nut to 17 Nm (145 inch lbs.) torque. 4. Bleed the base brakes hydraulic system. Refer to Brakes Service and Repair. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > With Antilock Brakes > Page 4295 Brake Proportioning/Combination Valve: Service and Repair Without Antilock Brakes Fig 35 Type 3 Proportioning Valve Identification Non-ABS Proportioning Valve Locations On Master Cylinder CAUTION: Proportioning valves should never be disassembled. GENERAL INFORMATION There are two proportioning valve assemblies used in each vehicle. Due to different thread sizes, each proportioning valve has a different part number. During any service procedures identify the proportioning valve assemblies by supplier part number and or the color identification band. If premature rear wheel skid occurs on hard brake application, it could be an indication that a malfunction has occurred with one of the proportioning valves. One proportioning valve controls the right rear brake, and the other proportioning valve controls the left rear brake. Therefore, a road test to determine which rear brake slides first is essential. If a malfunctioning proportioning valve is suspected on a vehicle. Refer to Testing and Inspection. REMOVE 1. Disconnect brake tube from proportioning valve requiring removal from the master cylinder. 2. Remove proportioning valve from the master cylinder requiring replacement. INSTALL 1. Wet 0-ring seal on new proportioning valve using clean fresh brake fluid. 2. Install proportioning valve in master cylinder and hand tighten until proportioning valve and 0-ring seal is fully seated in master cylinder. Torque proportioning valve to 40 Nm (30 ft. lbs.). 3. Install brake tube on proportioning valve. tighten tube nut to 17 Nm (145 in lbs.) torque. 4. Bleed the affected brake line. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > Page 4296 Brake Proportioning/Combination Valve: Tools and Equipment Proportioning Valve Pressure Test Fitting Proportioning Valve Pressure Test Gauge Set GENERAL INFORMATION The new in-line proportioning valves used on this vehicle, require new pressure fittings to test for proper proportioning valve function. The pressure fittings are installed before and after the proportioning valve being tested to verify proportioning valve is maintaining the required hydraulic pressure to the rear wheel brake which it controls. CONDITION If a condition of premature rear wheel skid occurs on a vehicle the proportioning valve should always be tested prior to it being replaced. This is due to the fact that there are conditions other then a faulty proportioning valve which can cause a premature rear wheel skid. TOOLS Testing proportioning valve pressures on a vehicle with or without ABS requires using the same special tools. There are 4 new Pressure Fittings, Special Tool 6805 or equivalent which are to be used for testing the proportioning valves. These same pressure fittings are used if the proportioning valves are either mounted in the HCU, on an antilock equipped vehicle, or in-line on the brake tube on non-antilock equipped vehicles. The pressure gauges used with the pressure test fittings for testing the in-line proportioning valves on both non-ABS and ABS brakes, is the Pressure Gauge Set, Special Tool C-4007-A, or equivalent currently used for testing the combination valve. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Specifications Hydraulic Control Unit: Specifications To Mounting Bracket Bolts .................................................................................................................. ............................................... 28 Nm (250 inch lbs.) Bracket To Frame Rail Mounting Bolt (Top) ...................................................................................................................................... 18 Nm (160 inch lbs.) Bracket To Frame Rail Mounting Bolts (Side) ................................................................................................................................... 22 Nm (200 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Specifications > Page 4300 Hydraulic Control Unit Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Specifications > Page 4301 Hydraulic Control Unit: Service Precautions WARNING: THE ONLY PARTS OF THE HYDRAULIC CONTROL UNIT (HCU) THAT ARE SERVICEABLE ARE THE RELAY BOX, THE PROPORTIONING VALVES, AND THE HCU MOUNTING BRACKET. THE REMAINING COMPONENTS OF THE HYDRAULIC CONTROL UNIT HCU ARE NOT SERVICEABLE ITEMS. NO ATTEMPT SHOULD EVER BE MADE TO REMOVE OR SERVICE ANY OTHER PARTS OF THE HYDRAULIC CONTROL UNIT HCU. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > General Information Hydraulic Control Unit: Description and Operation General Information Hydraulic Control Unit GENERAL INFORMATION The Hydraulic Control Unit (HCU) is located under the master cylinder and power brake booster and is mounted to the left frame rail. The HCU contains the following components for controlling the vehicle's braking system during Antilock Brake System (ABS) braking: 4 Decay Valves, 4 Shuttle Valves, 2 Fluid Sumps, a Pump/Motor and a relay box. Also attached to the HCU are the rear brake Proportioning Valves and the vehicles 6 hydraulic brake tubes. Decay Solenoids There are 4 decay solenoids, one for each wheel. In the released position they provide a fluid path from the master cylinder to the wheel brakes of the vehicle. In the actuated (decay) position, they provide a fluid path from wheel brakes of the vehicle to the sumps. The Decay solenoids are spring loaded in the released (build) position during normal braking. Shuttle Valves There are 4 Shuttle Valves, one for each wheel. The Shuttle Valve is a hydraulically actuated valve which shuttles when the decay solenoid and pump are energized. This places an orifice (restriction) in the line between the pump and the decay solenoid. This restriction provides a controlled build rate to each wheel brake during an ABS stop. The Shuttle Valve will remain in the orificed position until the ABS cycle is complete. When the ABS cycle has been completed the decay solenoids will return to their released position which will equalize the pressure across the Shuttle Valves. When the pressure equalizes, the spring loaded Shuttle Orifice valves will return to the unrestricted position. Fluid Sumps There are two fluid sumps in the HCU, one each for the primary and secondary hydraulic circuits. The fluid sumps temporarily store brake fluid that is decayed from the wheel brakes during an ABS cycle. This fluid is then delivered to the pump to provide build pressure. The typical pressure in the sumps is 50 psi, during ABS operation only. Pump Motor Assembly The HCU contains 2 Pump Assemblies, one each for the primary and secondary hydraulic circuits. Both pumps are driven by a common electric motor which is part of the HCU. The pumps pick up fluid from the sumps to supply build pressure to the brakes during an ABS stop. The motor only runs during an ABS stop and is controlled by the Controller Antilock Brake (CAB) via the Pump/Motor Relay. The Pump/Motor Assembly is not a serviceable item. If it requires service the HCU must be replaced. Relay Box ABX-4 utilizes two relays contained in a relay box mounted to the HCU. The relay box contains a System Relay and a Pump/Motor Relay. A single 10-way connector provides the electrical interface. The relay box is serviceable as an assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > General Information > Page 4304 Hydraulic Control Unit: Description and Operation Hydraulic Control Unit Decay Solenoids HYDRAULIC CONTROL UNIT DECAY SOLENOIDS There are 4 decay solenoids, one for each wheel. In the released position they provide a fluid path from the Master Cylinder to the wheel brakes of the vehicle. In the actuated (decay) position, they provide a fluid path from wheel brakes of the vehicle to the sumps. The Decay Solenoids are spring loaded in the released (build) position during normal braking. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > General Information > Page 4305 Hydraulic Control Unit: Description and Operation Hydraulic Control Unit Shuttle Valves HYDRAULIC CONTROL UNIT SHUTTLE VALVES There are 4 Shuttle Valves, one for each wheel. The Shuttle Valve is a hydraulically actuated valve which shuttles when the decay solenoid and pump are energized. This places an orifice (restriction) in the line between the pump and the decay solenoid. This restriction provides a controlled build rate to each wheel brake during an ABS stop. The Shuttle Valve will remain in the orificed position until the ABS cycle is complete. When the ABS cycle has been completed the decay solenoids will return to their released position which will equalize the pressure across the Shuttle Valves. When the pressure equalizes, the spring loaded Shuttle Orifice valves will return to the unrestricted position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > General Information > Page 4306 Hydraulic Control Unit: Description and Operation Hydraulic Modulator Circuit Operation CIRCUIT OPERATION The hydraulic modulator is used for the controlling of the brake system pressure to the wheels. The modulator is made up of four solenoids. Circuits involved are, B142 for the left front wheel, B143 for the right front wheel, B146 for the left rear wheel, and B148 for the right rear wheel. The solenoids use a common ground on the Z1 circuit. There are two Z1 circuits from the modulator. Both of these grounds terminate at the left headlamp ground, and are spliced in with the Anti Lock Brake System (ABS) pump motor and the ABS system relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement Hydraulic Control Unit: Service and Repair Hydraulic Control Unit (HCU) Replacement Removal PROCEDURE 1. Disconnect negative (ground) cable from the battery and isolate cable. Master Cylinder Fluid Level Sensor 2. Disconnect vehicle wiring harness connector from brake fluid level sensor at base of master cylinder brake fluid reservoir. Fig 7 Type 3 Primary And Secondary Output Ports. With ABS 3. Disconnect primary and secondary brake tubes from master cylinder housing. Install plugs at brake tube outlets of master cylinder assembly. 4. Clean area where master cylinder attaches to booster using a suitable brake cleaner. CAUTION: On ABS equipped vehicles, vacuum in power booster must be pumped down before removing master cylinder to prevent the booster from sucking in any contamination. This can be done simply by pumping the brake pedal, with the engine not running, until a firm brake pedal is achieved. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4309 Master Cylinder Mounting To Vacuum Booster 5. Remove the 2 nuts attaching master cylinder to power brake booster unit. 6. Slide master cylinder assembly straight out, and away from power brake booster unit. Electrical Connections To HCU And Relay Box 7. Disconnect the 6 way connector from the Hydraulic Control Unit (HCU) wiring harness and 10 way connector from the relay box located on the HCU. Primary And Secondary Brake Tubes From Master Cylinder To HCU 8. Remove the primary and secondary master cylinder brake tubes from the HCU. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4310 Proportioning Valve Location On Hydraulic Control Unit 9. Remove the chassis brake tubes from the proportioning valves and outlet ports of the (HCU). 10. Raise vehicle. Hydraulic Control Unit Mounting Bracket 11. Loosen and remove the 2 bolts attaching the HCU mounting bracket to the side of the front frame rail. 12. Lower vehicle. 13. Loosen and remove the bolts attaching the HCU mounting bracket to the top of the frame rail. 14. Remove HCU and its mounting bracket as an assembly from the vehicle. Installation PROCEDURE Hydraulic Control Unit Mounting Bracket 1. Install the Hydraulic Control Unit (HCU) and mounting bracket as an assembly, on left front frame rail of the vehicle, aligning tabs on mounting bracket with holes in frame rail. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4311 2. Install and loosely tighten the bolt attaching the HCU mounting bracket to the top of the frame rail. 3. Raise vehicle. 4. Install the 2 bolts attaching the HCU mounting bracket to the side of the front frame rail. Then torque both mounting bolts to 28 Nm (200 inch lbs.). 5. Lower vehicle. 6. Torque bolt attaching HCU mounting bracket to top of frame rail to 20 Nm (180 inch lbs.). Proportioning Valve Location On Hydraulic Control Unit 7. Install the 4 chassis brake tubes onto the proportioning valves and outlet ports of the HCU. Torque the 4 chassis brake tube nuts to 17 Nm (145 inch lbs.). Primary And Secondary Brake Tubes From Master Cylinder To HCU 8. Install primary and secondary brake tubes from the master cylinder onto the HCU, with tube nuts only hand tightened. Electrical Connections To HCU And Relay Box 9. Install vehicle wiring harness connectors onto the 10 way, and 6 way connectors, located on the relay box of the HCU. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4312 Removing Seal From Vacuum Booster 10. Remove vacuum seal located in the front of the power brake vacuum booster. Vacuum seal is removed by carefully inserting a small screw driver between the push rod of the power brake vacuum booster and vacuum seal and pry seal out of power brake vacuum booster. Do not attempt to pry seal out of master cylinder by inserting a tool between seal and power brake vacuum booster. 11. Remove old vacuum seal from master cylinder, if the vacuum seal came out of power brake vacuum booster when master cylinder was removed this step is not necessary. CAUTION: When replacing the master cylinder on a vehicle equipped with ABS, a NEW vacuum seal MUST be installed in the power brake vacuum booster. Use only the procedure detailed below for installing vacuum seal into power brake vacuum booster. Be sure old vacuum seal is removed from power brake vacuum booster before attempting to install new seal. CAUTION: When lubricating master cylinder push rod, use only Mopar Silicone Dielectric Compound. Using any other type of grease or lubricant on the push rod, will not provide adequate long term lubrication of the push rod. Lubricating Master Cylinder Push Rod 12. Lubricate master cylinder push rod as indicated only using Mopar Dielectric Grease-And No Substitutes. Fig 19 Type 3 Vacuum Seal Installation. Neon Models Equipped With ABS Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4313 Fig 20 Type 3 Vacuum Seal Seating. Neon Models Equipped With ABS 13. Install vacuum seal on master cylinder push rod as shown with notches on vacuum seal pointing toward master cylinder housing. Then slide vacuum seal onto master push rod until seal is seated against master cylinder housing before installing master cylinder on power brake vacuum booster. CAUTION: If vehicle is equipped with ABS, be sure old vacuum seal is removed from power brake vacuum booster before attempting to install master cylinder and NEW vacuum seal. If vacuum seal is not removed, refer to Brakes, Master Cylinder Service and Repair for required vacuum seal removal procedure. 14. Position master cylinder on studs of power brake unit, aligning push rod on power brake vacuum booster with master cylinder push rod. Master Cylinder Mounting To Vacuum Booster 15. Install the 2 master cylinder to power brake unit mounting nuts and torque to 28 Nm (250 inch lbs.). Fig 7 Type 3 Primary And Secondary Output Ports. With ABS 16. Connect brake tubes to master cylinder primary and secondary ports. Torque all tube nuts to 17 Nm (145 inch lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4314 Master Cylinder Fluid Level Sensor 17. Install the wiring harness connector on the master cylinder reservoir brake fluid level switch. 18. Bleed the base brakes and the ABS brakes hydraulic systems. Refer to Brakes Service and Repair and Antilock Brake System Service and Repair for the required procedures. 19. Road test vehicle to ensure proper operation of the base and ABS brake systems. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4315 Hydraulic Control Unit: Service and Repair Relay Box Replacement GENERAL INFORMATION The System Relay and Pump/Motor Relay are both serviced together as an assembly with the relay box. The relay box is mounted directly to the Hydraulic Control Unit (HCU). To remove the relay box from the HCU, the HCU requires removal from the vehicle. This is to allow visual access of the relay box to HCU electrical connection. Visual access to this connection is necessary to be sure connection is correctly made when installing relay box on the HCU. REMOVE 1. Disconnect negative (ground) cable from the battery and isolate the cable. 2. Remove the HCU from the vehicle. Refer to Hydraulic Control Unit Removal, for the required HCU removal procedure. Relay Box To HCU Mounting Screws 3. Unclip the 6 way wiring harness connector from the relay box. 4. Remove the 2 screws attaching the relay box assembly to the HCU. Remove only the 2 screws mounting the relay box to the HCU. Do not remove the pump motor mounting screws. Relay Box To HCU Electrical Connection 5. Grasp relay box. Without twisting or rocking, pull relay box away from pump motor housing until connector on relay box unplugs from the pump motor terminal. This is a tight connection, relay box will require a good amount of force to unplug from pump motor. 6. Remove relay box from HCU. INSTALL Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4316 Pump Motor To Relay Box Electrical Seal 1. Be sure electrical connector seal is installed in pump motor housing before installing relay box. If electrical connector seal is cracked, brittle or in any way damaged it must be replaced before installing relay box. 2. Position relay box on HCU and carefully align the terminals on the relay box with the terminals on the pump motor. 3. Grasp relay box with both hands. Then without twisting or rocking, push relay box onto the pump motor electrical connector as far as possible by hand. 4. Install and securely tighten the 2 screws attaching the relay box assembly to the HCU. 5. Reconnect the 6 way connector onto the relay box. 6. Install the HCU back in the vehicle. Refer to Hydraulic Control Unit Installation, for the required HCU installation procedure. 7. Connect the negative (-) ground cable back on the negative post of the battery. 8. Bleed the base brakes and the ABS brakes hydraulic systems. Refer to Brakes Service and Repair and Antilock Brake System Service and Repair for the required procedures. 9. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Mechanical Specifications Brake Master Cylinder: Mechanical Specifications With Antilock Brakes To Vacuum Booster Mounting Nut ..................................................................................................................................................... 28 Nm (250 inch lbs.) Without Antilock Brakes Master Cylinder To Booster Mounting Nuts .......................................................................................................................................... 28 Nm (250 in. lbs.) Brake Tubes To Master Cylinder Ports .................................................................................................................................................. 17 Nm (145 in. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Mechanical Specifications > Page 4321 Brake Master Cylinder: Fluid Type Specifications Fill brake fluid reservoir with brake fluid conforming to DOT 3 specifications such as Mopar or an equivalent. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4322 Master Cylinder Fluid Level Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4323 Brake Master Cylinder: Service Precautions CAUTION: - On ABS equipped vehicles, vacuum in power booster must be pumped down before removing master cylinder to prevent booster from sucking in any contamination. This can be done simply by pumping the brake pedal until a firm pedal is achieved, with the ignition off. - On vehicles equipped with ABS, the master cylinder is used to create the seal for holding vacuum in the power brake vacuum booster. The vacuum seal in the front of the power brake vacuum booster MUST be replaced whenever the master cylinder is removed from the power brake vacuum booster. - When replacing the master cylinder on a vehicle equipped with ABS, a NEW vacuum seal MUST be installed in the power brake vacuum booster. Use only the procedure detailed below for installing vacuum seal into power brake vacuum booster. Be sure old vacuum seal is removed from power brake vacuum booster before attempting to install new seal. - Then lubricating master cylinder push rod, use only Mopar Silicone Dielectric Compound. Using any other type of grease or lubricant on the push rod, will not provide adequate long term lubrication of the push rod. - If vehicle is equipped with ABS, be sure old vacuum seal is removed from power brake vacuum booster before attempting to install master cylinder and NEW vacuum seal. If vacuum seal is not removed, refer to Removal. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > With Antilock Brakes Brake Master Cylinder: Description and Operation With Antilock Brakes Master Cylinder Assembly GENERAL INFORMATION The Bendix ABX-4 Brake System uses a modified Master Cylinder and Power Brake Vacuum Booster assembly. The Master Cylinder primary and secondary outputs go directly to the Hydraulic Control Unit (HCU). The vehicle uses screw-in proportioning valves at the Hydraulic Control Unit (HCU) instead of the combination valve used in prior designs. With this new design, the chassis brake tubes connect directly from the HCU to the brake flex hose. This vehicle uses a center valve design master cylinder and has a two outlet design with the screw-in proportioning valves attached directly to the HCU. Vehicles equipped with rear drum brakes use a master cylinder with a 21 mm bore diameter, while vehicles equipped with rear disc brake use a 7/8" bore master cylinder. DESIGN The brake system master cylinder assembly consists of the following components. The body of the master cylinder is an anodized aluminum casting. It has a machined bore to accept the master cylinder piston and threaded ports with seats for hydraulic brake line connections. The brake fluid reservoir of the master cylinder assembly is made of a see through polypropylene type plastic. The primary outlet port supplies hydraulic pressure to the right front and left rear brakes. The secondary outlet port supplies hydraulic pressure to the left front and right rear brakes. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > With Antilock Brakes > Page 4326 Brake Master Cylinder: Description and Operation Without Antilock Brakes Fig 4 Type 3 Master Cylinder. Less ABS Non ABS Master Cylinder Primary And Secondary Ports GENERAL INFORMATION This vehicle is available with three different master cylinders. The vehicle uses screw-in proportioning valves at the master cylinder instead of the combination valve used in prior designs. With this new design, the chassis brake tubes connect directly from the master cylinder to the brake flex hose. A standard compensating port designis used. The master cylinder has a four outlet design with two screw-in proportioning valves attached directly to the inboard side of the master cylinder housing. The ABS master cylinders are a two outlet design with the screw-in proportioning valves attached directly to the HCU. Vehicles equipped with rear drum brakes use a master cylinder with a 21 mm bore diameter, while vehicles equipped with rear disc brake use a 7/8" bore master cylinder. DESIGN The brake system master cylinder assembly consists of the following components. The body of the master cylinder is an anodized aluminum casting. It has a machined bore to accept the master cylinder piston and threaded ports with seats for hydraulic brake line connections. The brake fluid reservoir of the master cylinder assembly is made of a see through polypropylene type plastic. The primary outlet ports supply hydraulic pressure to the left front and right rear brakes. The secondary outlet ports supply hydraulic pressure to the right front and left rear brakes. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Brake Master Cylinder: Service and Repair Master Cylinder Bleeding Bench Bleeding Bleeding Tubes Attached To ABS Master Cylinder Bleeding Tubes Attached To Non-ABS Master Cylinder Bleeding Master Cylinder PROCEDURE 1. Clamp the master cylinder in a vise. Attach Bleeding Tubes, Special Tool 6802, or equivalent to the master cylinder outlet ports. Position bleeding tubes so the outlets of the bleeding tubes will be below the surface of the brake fluid when reservoir is filled to proper level. 2. Fill brake fluid reservoir with brake fluid conforming to DOT 3 specifications such as Mopar or an equivalent. 3. Using a wooden dowel. Depress push rod slowly, and then allow pistons to return to the released position. Continue to repeat this step several times after no more air bubbles are expelled from bleed tubes to ensure all air is bled from the master cylinder. 4. Remove bleeding tubes from master cylinder outlet ports, plug outlet ports and install fill cap on reservoir. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4329 5. Remove master cylinder from vise. NOTE: It is not necessary to bleed the brakes entire hydraulic system after replacing the master cylinder. However, the master cylinder must have been thoroughly bled and filled to the proper level upon installation on the power brake vacuum booster. Manual Bleeding Air Trapped In Brake System Method For Purging Air From Brake System Bleeder Screw CAUTION: - Before removing the Master Cylinder cover, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder. NOTE: - For bleeding the ABS hydraulic system, refer to Hydraulic Control Unit. - Correct bleeding of the brakes hydraulic system without the use of pressure bleeding equipment will require the aid of a helper. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4330 BLEEDING BRAKES WITHOUT A PRESSURE BLEEDER The following wheel sequence for bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulic system. ^ Left rear wheel ^ Right front wheel ^ Right rear wheel ^ Left front wheel 1. Attach a clear plastic hose to the bleeder screw starting at the right rear wheel and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. 2. Pump the brake pedal three or four times and hold it down before the bleeder screw is opened. 3. Open the bleeder screw at least 1 full turn. When the bleeder screw opens the brake pedal will drop. 4. Close the bleeder screw. Release the brake pedal only after the bleeder screw is closed. 5. Repeat steps 1 through 3, four or five times at each bleeder screw. Then check the pedal for travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to monitor the fluid level in the master cylinder reservoir. It must stay at the proper level so air will not be allowed to re-enter the brake system. 6. Test drive vehicle to be sure brakes are operating correctly and that pedal is solid. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4331 Brake Master Cylinder: Service and Repair Master Cylinder Replacement Removal PROCEDURE CAUTION: On ABS equipped vehicles, vacuum in power booster must be pumped down before removing master cylinder to prevent booster from sucking in any contamination. This can be done simply by pumping the brake pedal until a firm pedal is achieved, with the ignition off. 1. On ABS equipped vehicles, be sure engine is not running, and pump the brake pedal until a firm pedal is achieved (4-5 strokes). Master Cylinder Fluid Level Sensor 2. Remove vehicle wiring harness connector, from brake fluid level sensor, in master cylinder brake fluid reservoir. Primary And Secondary Brake Tubes Without ABS Brakes 3. Disconnect the primary and secondary brake tubes from the master cylinder. Install plugs at all open brake tube outlets on master cylinder assembly. 4. On vehicles equipped with ABS, clean area where master cylinder attaches to booster using a suitable brake cleaner product such as Mopar Brake Parts Cleaner or an equivalent. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4332 Master Cylinder Mounting To Vacuum Booster 5. Remove the 2 nuts attaching master cylinder housing to power brake vacuum booster. 6. Slide master cylinder assembly straight out of the power brake vacuum booster. CAUTION: On vehicles equipped with ABS, the master cylinder is used to create the seal for holding vacuum in the power brake vacuum booster. The vacuum seal in the front of the power brake vacuum booster MUST be replaced whenever the master cylinder is removed from the power brake vacuum booster. Removing Seal From Vacuum Booster 7. If vehicle is equipped with ABS, remove vacuum seal located in the front of the power brake vacuum booster. Vacuum seal is removed by carefully inserting a small screw driver between the push rod of the power brake vacuum booster and vacuum seal and pry seal out of power brake vacuum booster. Do not attempt to pry seal out of master cylinder by inserting a tool between seal and power brake vacuum booster. Installation PROCEDURE CAUTION: When replacing the master cylinder on a vehicle equipped with ABS, a NEW vacuum seal MUST be installed in the power brake vacuum booster. Use only the procedure detailed below for installing vacuum seal into power brake vacuum booster. Be sure old vacuum seal is removed from power brake vacuum booster before attempting to install new seal. CAUTION: Then lubricating master cylinder push rod, use only Mopar Silicone Dielectric Compound. Using any other type of grease or lubricant on the push rod, will not provide adequate long term lubrication of the push rod. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4333 Lubricating Master Cylinder Push Rod 1. Lubricate master cylinder push rod as indicated in only using Mopar Dielectric Grease-And No Substitutes. Refer to the Mopar Chemicals Catalog to obtain the required lubricant. Fig 19 Type 3 Vacuum Seal Installation. Neon Models Equipped With ABS Fig 20 Type 3 Vacuum Seal Seating. Neon Models Equipped With ABS 2. Install vacuum seal on master cylinder push rod as shown with notches on vacuum seal pointing toward master cylinder housing. Then slide vacuum seal onto master push rod until seal is seated against master cylinder housing before installing master cylinder on power brake vacuum booster. CAUTION: If vehicle is equipped with ABS, be sure old vacuum seal is removed from power brake vacuum booster before attempting to install master cylinder and NEW vacuum seal. If vacuum seal is not removed, refer to Removal. 3. Position master cylinder on studs of power brake unit, aligning push rod on power brake vacuum booster with master cylinder push rod. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4334 Master Cylinder Mounting To Vacuum Booster 4. Install the 2 master cylinder to power brake unit mounting nuts and torque to 28 Nm (250 in. lbs.). Primary And Secondary Brake Tubes Without ABS Brakes 5. Connect brake tubes to master cylinder primary and secondary ports. Torque all tube nuts to 17 Nm (145 in. lbs.). Removal PROCEDURE CAUTION: On ABS equipped vehicles, vacuum in power booster must be pumped down before removing master cylinder to prevent booster from sucking in any contamination. This can be done simply by pumping the brake pedal until a firm pedal is achieved, with the ignition off. 1. On ABS equipped vehicles, be sure engine is not running, and pump the brake pedal until a firm pedal is achieved (4-5 strokes). Master Cylinder Fluid Level Sensor 2. Remove vehicle wiring harness connector, from brake fluid level sensor, in master cylinder brake fluid reservoir. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4335 Fig 7 Type 3 Primary And Secondary Output Ports. With ABS 3. Disconnect the primary and secondary brake tubes from the master cylinder. Install plugs at all open brake tube outlets on master cylinder assembly. 4. On vehicles equipped with ABS, clean area where master cylinder attaches to booster using a suitable brake cleaner product such as Mopar Brake Parts Cleaner or an equivalent. Master Cylinder Mounting To Vacuum Booster 5. Remove the 2 nuts attaching master cylinder housing to power brake vacuum booster. 6. Slide master cylinder assembly straight out of the power brake vacuum booster. CAUTION: On vehicles equipped with ABS, the master cylinder is used to create the seal for holding vacuum in the power brake vacuum booster. The vacuum seal in the front of the power brake vacuum booster MUST be replaced whenever the master cylinder is removed from the power brake vacuum booster. Removing Seal From Vacuum Booster 7. If vehicle is equipped with ABS, remove vacuum seal located in the front of the power brake vacuum booster. Vacuum seal is removed by Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4336 carefully inserting a small screw driver between the push rod of the power brake vacuum booster and vacuum seal and pry seal out of power brake vacuum booster. Do not attempt to pry seal out of master cylinder by inserting a tool between seal and power brake vacuum booster. Installation PROCEDURE CAUTION: When replacing the master cylinder on a vehicle equipped with ABS, a NEW vacuum seal MUST be installed in the power brake vacuum booster. Use only the procedure detailed below for installing vacuum seal into power brake vacuum booster. Be sure old vacuum seal is removed from power brake vacuum booster before attempting to install new seal. CAUTION: Then lubricating master cylinder push rod, use only Mopar Silicone Dielectric Compound. Using any other type of grease or lubricant on the push rod, will not provide adequate long term lubrication of the push rod. Lubricating Master Cylinder Push Rod 1. Lubricate master cylinder push rod as indicated in only using Mopar Dielectric Grease-And No Substitutes. Refer to the Mopar Chemicals Catalog to obtain the required lubricant. Fig 19 Type 3 Vacuum Seal Installation. Neon Models Equipped With ABS Fig 20 Type 3 Vacuum Seal Seating. Neon Models Equipped With ABS 2. Install vacuum seal on master cylinder push rod as shown with notches on vacuum seal pointing toward master cylinder housing. Then slide Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4337 vacuum seal onto master push rod until seal is seated against master cylinder housing before installing master cylinder on power brake vacuum booster. CAUTION: If vehicle is equipped with ABS, be sure old vacuum seal is removed from power brake vacuum booster before attempting to install master cylinder and NEW vacuum seal. If vacuum seal is not removed, refer to Master Cylinder Removal in this section of the service manual for required vacuum seal removal procedure. 3. Position master cylinder on studs of power brake unit, aligning push rod on power brake vacuum booster with master cylinder push rod. Master Cylinder Mounting To Vacuum Booster 4. Install the 2 master cylinder to power brake unit mounting nuts and torque to 28 Nm (250 in. lbs.). Fig 7 Type 3 Primary And Secondary Output Ports. With ABS 5. Connect brake tubes to master cylinder primary and secondary ports. Torque all tube nuts to 17 Nm (145 in. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4338 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement Removing Fluid Reservoir from Master Cylinder NOTE: To replace the master cylinder brake fluid reservoir on this vehicle, it is not necessary to remove the master cylinder from the power brake vacuum booster. 1. Using Mopar, Brake Parts Cleaner or an equivalent, thoroughly clean the master cylinder and brake fluid reservoir. 2. Remove the brake fluid reservoir filler cap. 3. Using a syringe or equivalent type tool, empty as much brake fluid as possible from the reservoir. CAUTION: Do not pry fluid reservoir off master cylinder using a tool, damage to the reservoir or master cylinder can result. 4. Remove brake fluid reservoir from master cylinder by rocking the reservoir from side to side while pulling upward on the fluid reservoir. 5. Remove master cylinder housing to brake fluid reservoir sealing grommets. CAUTION: To ensure a leak proof seal when installing a fluid reservoir, never reuse the original fluid reservoir to master cylinder sealing grommets. 6. Install new master cylinder housing to brake fluid reservoir sealing grommets in master cylinder housing. 7. Lubricate reservoir mounting area with fresh clean brake fluid. Place reservoir in position over grommets. Seat reservoir into grommets using a rocking motion while firmly pressing down on fluid reservoir. 8. Be sure reservoir is positioned properly. 9. Make sure bottom of fluid reservoir touches top of both sealing grommets. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Page 4339 Brake Master Cylinder: Tools and Equipment Handle C-4171 Special Tools C-4689 Special Tools 6802 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder 115 in.lb Tube Nut 145 in.lb Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Page 4343 Rear Wheel Cylinder (Exploded View) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Page 4344 Wheel Cylinder: Service Precautions NOTE: When installing wheel cylinder on brake support plate, be sure it is positioned squarely (horizontal) to the brake shoe assemblies. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. 3. Remove rear brake drum. 4. Remove rear brake shoe assemblies from the brake support plate. Refer to Brake Shoe Service and Repair Removal. 5. If brake shoes are wet with grease or brake fluid, remove and replace. 6. Disconnect the rear brake flex hose from the wheel cylinder. 7. Remove rear wheel cylinder attaching bolts. 8. Remove rear wheel cylinder assembly from brake support plate. INSTALL 1. Apply a small bead of silicone sealer around the mating surface of the wheel cylinder to brake support plate. NOTE: When installing wheel cylinder on brake support plate, be sure it is positioned squarely (horizontal) to the brake shoe assemblies. 2. Install wheel cylinder onto brake support plate. Tighten the attaching bolts to 13 Nm (115 in. lbs.). 3. Hand start hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to 17 Nm (145 in. lbs.). 4. Install rear brake shoe assemblies on the brake support plate. Refer to Brake Shoe Service and Repair Installation. 5. Install rear brake drum onto rear hub. 6. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 109 - 150 Nm (80 - 110 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4347 7. Adjust the rear brakes. 8. Bleed the entire brake system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4348 Wheel Cylinder: Service and Repair Cleaning and Inspection With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. Visually check the boots for cuts, tears, or heat cracks. If any of these conditions exist, the wheel cylinders should be completely cleaned, inspected and new parts installed. If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid, the brake shoes must be replaced. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4349 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul Fig 3 Wheel Cylinder DISASSEMBLE To disassemble the wheel cylinders, proceed as follows: 1. Pry boots away from cylinders and remove. 2. Press IN on one piston to force out opposite piston, cup and spring. Then using a soft tool such as a dowel rod, press out the cup and piston that remain in the wheel cylinder. 3. Wash wheel cylinder, pistons, and spring in clean brake fluid or alcohol; DO NOT USE ANY PETROLEUM BASE SOLVENTS. clean thoroughly and blow dry with compressed air. Inspect cylinder bore and piston for scoring and pitting. Do not use a rag as lint from the rag will stick to bore surfaces.. 4. Wheel cylinder bores and pistons that are badly scored or pitted should be replaced. Cylinder walls that have light scratches, or show signs of corrosion, can usually be cleaned with crocus cloth, using a circular motion. Black stains on the cylinder walls are caused by piston cups and will not impair operation of cylinder. ASSEMBLE Before assembling the pistons and new cups in the wheel cylinders, dip them in clean brake fluid. If the boots are deteriorated, cracked or do not fit tightly on the pistons or the cylinder casting, install new boots. 1. Coat cylinder bore with clean brake fluid. 2. Lightly coat the sealing lip and outer surfaces of the wheel cylinder cups with Mopar Protect-A-Cup Lubricant. 3. Install expansion spring with cup expanders in cylinder. Install cups in each end of cylinder with open end of cups facing each other. 4. Install piston in each end of cylinder having the flat face of each piston contacting the flat face of each cup, already installed. 5. Coat the interior surfaces of the push on boots with the Mopar Protect-A-Cup Lubricant 6. Install a boot over each end of cylinder. Be careful not to damage boot during installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service Precautions Parking Brake Cable: Service Precautions WARNING: WHEN REPAIRS TO THE PARK BRAKE HAND LEVER ASSEMBLY OR CABLES IS REQUIRED, THE AUTO ADJUSTER MUST BE PRELOADED AND LOCKED OUT. NOTE: Remove only one rear park brake cable from rear brakes at a time. Failure to do so will result in high efforts required to connect park brake cables to equalizer or park brake lever at rear wheel brakes. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal Parking Brake Cable: Service and Repair Cable Removal NOTE: Remove only one rear park brake cable from rear brakes at a time. Failure to do so will result in high efforts required to connect park brake cables to equalizer or park brake lever at rear wheel brakes. PROCEDURE Attaching Screws At Rear Of Center Console With Out Arm Rest Attaching Screws At Rear Of Center Console With Arm Rest 1. Remove screws attaching rear of center console assembly to floor pan of vehicle. Attaching Screws At Front Of Center Console 2. Remove the 2 screws located in cup holders attaching front of center console to console bracket. 3. Raise park brake lever as high as it will go for the clearance required to remove the center console. 4. Remove center console assembly from vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4356 WARNING: WHEN REPAIRS TO THE PARK BRAKE HAND LEVER ASSEMBLY OR CABLES IS REQUIRED, THE AUTO ADJUSTER MUST BE PRELOADED AND LOCKED OUT. 5. Lower park brake lever handle. Locking Pin Installed In Park Brake Lever 6. Grasp park lever output cable by hand and pull rearward. Continue pulling on cable until a 3/16 in. drill bit can be inserted into handle and sector gear of park brake mechanism. This will lock the park brake mechanism and take tension off park brake cables. Park Brake Cables At Equalizer 7. Remove rear park brake cables from the park brake cable equalizer. 8. Remove rear seat cushion from vehicle. Rear Door Sill Scuff Plates Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4357 9. Remove scuff plates from right and left rear door sills. Scuff plates are attached to door sills using clips on bottom of scuff plates. Remove by carefully prying scuff plate retaining clips out of door sills. 10. Fold rear carpeting forward to expose park brake cables. Compressing Park Brake Cable Retaining Tabs 11. Install the box end of a 1/2 in. wrench over the park brake cable retainer as indicated. This will compress tabs on park brake cable retainer, allowing cable to be removed from console bracket. From under carpet, grasp park brake cable housing and pull cable straight out of console bracket. 12. Raise vehicle on jackstands or centered on a frame contact type hoist. 13. Remove rear wheel and tire assembly. Rear Brake Drum Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4358 Rear Brake Rotor 14. On vehicles equipped with rear drum brakes, remove brake drum from rear hub/bearing assembly. On vehicles equipped with rear disc brakes, remove disc brake caliper from disc brake adapter, and then remove rotor from hub/ bearing assembly. Rear Hub/Bearing Dust Cap Removal 15. Remove dust cap from rear hub/ bearing assembly. Hub/Bearing Assembly Retaining Nut 16. Remove hub/bearing assembly retaining nut. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4359 Hub/Bearing Removal From Spindle (Drum Brakes Shown) 17. Remove the rear hub/bearing assembly from the rear spindle. Park Brake Cable Attachment To Actuating Lever Brake Adjustment Lever Actuating Spring 18. On vehicles equipped with rear drum brakes, remove park brake cable from park brake actuating lever. Then remove the actuating spring between brake shoe adjustment lever and brake shoe assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4360 Parking Brake Shoe Assemblies Parking Brake Actuator Lever 19. On vehicles equipped with rear disc brakes, remove brake shoe assemblies from rear disc brake adapter. Then remove parking brake actuating lever from the park brake cable. Park Brake Cable Removal From Brake Support Plate 20. On vehicles equipped with rear drum brakes, remove park brake cable from rear brake support plate. Park brake cable is removed from brake support plate using a 1/2 in. wrench as shown above to compress locking tabs on park brake cable retainer. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4361 Park Brake Cable Removal From Disc Brake Adapter 21. On vehicles equipped with rear disc brakes, remove park brake cable from rear disc brake adapter. Park brake cable is removed from disc brake adapter using a screwdriver as shown to compress locking tabs on park brake cable retainer. Park Brake Cable Routing Bracket 22. Remove park brake cable routing bracket from vehicle frame rail. Park Brake Cable Seal At Floor Pan 23. Remove park brake cable and sealing grommet from floor pan of vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4362 Parking Brake Cable: Service and Repair Cable Installation PROCEDURE 1. Install park brake cable into floor pan of vehicle making sure sealing grommet is installed in floor pan as far as possible to insure proper seal. 2. Install park brake cable into brake support plate or rear disc brake adapter. Be sure locking tabs on cable retainer are expanded to ensure park brake cable is securely held in support plate or adapter. Park Brake Cable Routing Bracket 3. Install park brake cable routing bracket on frame rail. Install and securely tighten routing bracket attaching bolt. Park Brake Cable Attachment To Actuating Lever Brake Adjustment Lever Actuating Spring 4. On vehicles equipped with rear drum brakes, install park brake cable on park brake cable actuating lever. Then install actuating spring between brake shoe assembly and brake adjustment lever. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4363 Parking Brake Shoe Assemblies Parking Brake Actuator Lever 5. On vehicles equipped with rear disc brakes, install park brake shoes actuator lever on park brake cable. Then install park brake shoe assemblies on disc brake adapter. 6. Install the hub/bearing assembly on the rear spindle. Then install A NEW rear hub/bearing assembly retaining nut. Torque hub/bearing assembly retaining nut to 217 Nm (160 ft. lbs.). 7. Install hub/bearing assembly dust cap, using a soft faced hammer. 8. On drum brake equipped vehicles, install rear brake drum on hub/bearing assembly. On vehicles equipped with rear disc brakes, install rotor on hub/ bearing assembly. Rear Caliper Guide Pin Bolts 9. On disc brake equipped vehicles install disc brake caliper on disc brake adapter. Install the 2 caliper guide pin bolts and torque to 22 Nm (192 in. lbs.). Refer to Disc Brake Caliper Service and Repair for installation procedure. 10. Install rear wheel and tire assembly on vehicle, tighten all wheel stud nuts in crisscross pattern to one-half specified torque. Then repeat pattern, fully tightening stud nuts to 109 - 150 Nm (80 - 110 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4364 11. Lower vehicle. Seal Grommet Installation In Floor Pan 12. Grasp park brake cable to floor pan seal grommet by hand, and pull it into floor pan to ensure seal grommet is fully seated into floor pan. Park Brake Cable Installed In Retaining Bracket 13. Route park brake cable under carpeting and up to park brake cable retaining bracket on floor pan. Then install park brake cable into retaining bracket. Be sure tabs on park brake cable retainer, have expanded out to hold park brake cable in retaining bracket. Park Brake Cables At Equalizer 14. Install rear park brake cables into equalizer on park brake lever cable. 15. Reposition rear carpeting. 16. Install both rear door sill plate scuff moldings, by snapping them onto rear door sills. 17. Install lower rear seat cushion. Be sure lower seat cushion is fully installed in retainers on floor pan of vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4365 Removing Lockout Pin From Park Brake Lever 18. Firmly grasp park brake lever locking pin (3/16 in. drill bit) and quickly remove it from the park brake lever mechanism. This will allow the park brake lever mechanism to correctly adjust the park brake cables. 19. Cycle park brake lever ounce to position park brake cables. Then return the park brake lever to its released position. Check the rear wheels of the vehicle, they should rotate freely without dragging. 20. Apply park brake to full engagement. 21. Install center console assembly. 22. Install the center console assembly attaching screws. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service Precautions > Technician Safety Information Parking Brake Lever: Technician Safety Information WARNING: THE AUTO ADJUSTING FEATURE OF THIS PARKING BRAKE LEVER ASSEMBLY CONTAINS A CLOCK SPRING LOADED TO APPROXIMATELY 20 POUNDS. DO NOT RELEASE THE AUTO ADJUSTER LOCKOUT DEVICE BEFORE INSTALLING CABLES INTO THE EQUALIZER. KEEP HANDS OUT OF AUTO ADJUSTER SECTOR AND PAWL AREA. FAILURE TO OBSERVE CAUTION IN HANDLING THIS MECHANISM COULD LEAD TO SERIOUS INJURY. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service Precautions > Technician Safety Information > Page 4370 Parking Brake Lever: Vehicle Damage Warnings WARNING: WHEN REPAIRS TO THE PARK BRAKE HAND LEVER ASSEMBLY OR CABLES IS REQUIRED, THE AUTO ADJUSTER MUST BE RELOADED AND LOCKED OUT. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Removal Parking Brake Lever: Service and Repair Parking Brake Lever Removal Brake Lever Assembly And Output Cable WARNING: THE AUTO ADJUSTING FEATURE OF THIS PARKING BRAKE LEVER ASSEMBLY CONTAINS A CLOCK SPRING LOADED TO APPROXIMATELY 20 POUNDS. DO NOT RELEASE THE AUTO ADJUSTER LOCKOUT DEVICE BEFORE INSTALLING CABLES INTO THE EQUALIZER. KEEP HANDS OUT OF AUTO ADJUSTER SECTOR AND PAWL AREA. FAILURE TO OBSERVE CAUTION IN HANDLING THIS MECHANISM COULD LEAD TO SERIOUS INJURY. PARK BRAKE LEVER OUTPUT CABLE On this vehicle, the park brake lever output cable is not replaceable as a separate component of the park brake lever. Never attempt to repair the park brake output cable in any manner. Attaching Screws At Rear Of Center Console With Out Arm Rest Attaching Screws At Rear Of Center Console With Arm Rest Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Removal > Page 4373 PROCEDURE 1. Remove the screws attaching the rear of the center console assembly to console bracket. Attaching Screws At Front Of Center Console 2. Remove the 2 screws located in cup holders, attaching front of center console assembly to console bracket. 3. Raise park brake hand lever as high as it will go to get the required clearance to remove the center console. 4. Remove center console assembly. WARNING: WHEN REPAIRS TO THE PARK BRAKE HAND LEVER ASSEMBLY OR CABLES IS REQUIRED, THE AUTO ADJUSTER MUST BE RELOADED AND LOCKED OUT. 5. Lower park brake lever handle. Locking Pin Installed In Park Brake Lever 6. Grasp park brake lever output cable by hand and pull rearward. Continue pulling on cable until a 3/16 in. drill bit can be inserted into handle and sector gear of park brake mechanism. This will lock the park brake mechanism and take tension off park brake cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Removal > Page 4374 Park Brake Cables At Equalizer 7. Remove both rear park brake cables from the park brake cable equalizer. Brake Warning Lamp Connection To Park Brake Lever 8. Remove wiring harness electrical connector for brake warning light ground from the park brake lever. Park Brake Lever Attachment To Console Bracket 9. Remove the 2 nuts attaching the park brake lever to the console bracket. Remove park brake lever mechanism from vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Removal > Page 4375 Parking Brake Lever: Service and Repair Parking Brake Lever Installation WARNING: THE AUTO ADJUSTING FEATURE OF THIS PARKING BRAKE LEVER ASSEMBLY CONTAINS A CLOCK SPRING LOADED TO APPROXIMATELY 20 POUNDS. DO NOT RELEASE THE AUTO ADJUSTER LOCKOUT DEVICE BEFORE INSTALLING CABLES INTO THE EQUALIZER. KEEP HANDS OUT OF AUTO ADJUSTER SECTOR AND PAWL AREA. FAILURE TO OBSERVE CAUTION IN HANDLING THIS MECHANISM COULD LEAD TO SERIOUS INJURY. PROCEDURE Park Brake Lever Attachment To Console Bracket 1. Place park brake lever on console bracket. Install and securely tighten the 2 attaching nuts. Park Brake Cables At Equalizer 2. Install both rear park brake cables into equalizer on park brake lever output cable. 3. Ensure that park brake cable is correctly installed and aligned with cable track on park brake lever. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Removal > Page 4376 Removing Lockout Pin From Park Brake Lever 4. Firmly grasp park brake lever locking pin and quickly remove it from the park brake lever mechanism. This will allow the park brake lever mechanism to correctly adjust the park brake cables. Brake Warning Lamp Connection To Park Brake Lever 5. Connect electrical connector for brake warning lamp onto terminal on park brake lever assembly. 6. Cycle park brake lever once to position park brake cables. Then return the park brake lever its released position. Check the rear wheels of the vehicle. They should rotate freely without dragging. 7. Raise park brake lever to its fully engaged position. This is necessary to allow installation of the center console. 8. Install center console assembly Attaching Screws At Rear Of Center Console With Out Arm Rest Attaching Screws At Rear Of Center Console With Arm Rest Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Removal > Page 4377 Attaching Screws At Front Of Center Console 9. Install the 4 center console assembly attaching screws. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Description and Operation Parking Brake Shoe: Description and Operation Parking Brake Assembly For Rear Disc Brake The parking brakes on vehicles equipped with rear disc brakes consist of a small duo-servo brake assembly mounted to the disc brake caliper adapter. The hat (center) section of the rear rotor serves as the braking surface (drum) for the parking brakes. This park brake application uses the same operating cable configuration as the drum brake equipped vehicles, but different cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal Parking Brake Shoe: Service and Repair Removal PROCEDURE 1. Remove rear disc brake caliper assembly from adapter and rotor. See: Disc Brake System/Brake Caliper/Service and Repair 2. Remove rear rotor from rear hub. 3. Remove dust cap from rear hub. 4. Remove rear hub and bearing assembly retaining nut and washer. 5. Remove rear hub and bearing assembly from rear spindle. Rear Brake Shoe Hold-Down Clip 6. Remove rear brake shoe assembly hold down clip. 7. Turn brake shoe adjuster wheel until adjuster is at shortest length. Park Brake Shoe Adjuster Assembly 8. Remove adjuster assembly from the parking brake shoe assemblies. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 4383 Brake Shoe Lower Return Spring 9. Remove lower shoe to shoe spring. Brake Shoe And Upper Spring 10. Pull rear brake shoe assembly away from anchor. Then remove rear brake shoe and upper spring. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 4384 Front Hold Down Clip And Brake Shoe 11. Remove front brake shoe hold-down clip. Then remove front brake shoe assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 4385 Parking Brake Shoe: Service and Repair Installation PROCEDURE Front Hold Down Clip And Brake Shoe 1. Install front brake shoe and hold down clip. Brake Shoe And Upper Spring 2. Install rear brake shoe and the upper brake shoe to shoe return spring. 3. Pull rear brake shoe over anchor block until properly located on adapter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 4386 Brake Shoe Lower Return Spring 4. Install the lower shoe to shoe return spring. Park Brake Shoe Adjuster Assembly 5. Install brake shoe adjuster assembly with star wheel rearward. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 4387 Rear Brake Shoe Hold-Down Clip 6. Install rear brake shoe hold down clip. 7. Adjust brake shoes to a diameter to 171 mm (6.75 inch). 8. Install rear hub and bearing assembly on spindle. 9. Install A NEW hub and bearing assembly retaining nut. Torque the hub and bearing assembly retaining nut to 168 Nm (124 ft. lbs.). 10. Install hub and bearing assembly dust cap. 11. Install rear rotor. 12. Install rear disc brake caliper on the adapter. 13. Install wheel and tire assemblies. 14. Tighten wheel stud nuts to 109 150 Nm (80 - 110 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Master Cylinder Mounting Nuts ............................................................................................................................................................ 28 Nm (250 in. lbs.) Power Brake Vacuum Booster Mounting Nuts ...................................................................................................................................... 29 Nm (250 in. lbs.) Tube Nuts ............................................................................................................................... ................................................................ 17 Nm (145 in. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4392 Vacuum Brake Booster: Service Precautions CAUTION: When installing the routing clip and brake tubes on the mounting stud, do not bend or kink the chassis brake line tubes. Be sure the chassis brake tubes are routed correctly. The chassis brake tubes can not touch each other or other components or the body of the vehicle. NOTE: The vacuum booster assembly is not a repairable part and must be replaced as a complete unit if it is found to be faulty in any way. The vacuum brake booster check valve is not repairable but can be replaced as a component of the vacuum booster. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4393 Vacuum Brake Booster: Description and Operation Vacuum Booster Identification Vacuum Booster Assembly GENERAL INFORMATION All vehicles use a 230 mm single diaphragm power brake vacuum booster. There are however two different booster designs; one for vehicles equipped with ABS and one for vehicles without ABS. These two boosters differ at the interface to the master cylinder. If the power brake booster requires replacement be sure it is replaced with the correct part. The power brake booster can be identified by the tag attached to the body of the booster assembly. This tag contains the following information: The production part number of the power booster assembly, the date it was built, who manufactured it, and brake sales code. The power brake booster reduces the amount of force required by the driver to obtain the necessary hydraulic pressure to stop vehicle. The power brake booster is vacuum operated. The vacuum is supplied from the intake manifold on the engine through the power brake booster check valve. NOTE: The power brake booster assembly is not a repairable part and must be replaced as a complete unit if it is found to be faulty in any way. The power booster vacuum check valve is not repairable but can be replaced as an assembly. PURPOSE As the brake pedal is depressed, the power booster input rod moves forward. This opens and closes valves in the power booster, allowing atmospheric pressure to enter on one side of a diaphragm. Engine vacuum is always present on the other side. This difference in pressure forces the output rod of the power booster out against the primary piston of the master cylinder. As the pistons in the master cylinder move forward this creates the hydraulic pressure in the brake system. Different engine options available for this vehicle require that different vacuum hose routings be used. LOCATION The power brake vacuum booster assembly mounts on the engine side of the dash panel. It is connected to the brake pedal by the input push rod. A vacuum line connects the power booster to the intake manifold. The master cylinder is bolted to the front of the power brake vacuum booster assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal Vacuum Brake Booster: Service and Repair Removal PROCEDURE CAUTION: On ABS equipped vehicles, vacuum in power booster must be pumped down before removing master cylinder to prevent booster from sucking in any contamination. This can be done simply by pumping the brake pedal until a firm pedal is achieved, with the ignition off. 1. On ABS equipped vehicles, with engine not running, pump the brake pedal until a firm pedal is achieved (4-5 strokes). Master Cylinder Fluid Level Sensor 2. Remove vehicle wiring harness connector from brake fluid level sensor located in master cylinder brake fluid reservoir. Primary And Secondary Brake Tubes Without ABS Brakes Fig 7 Type 3 Primary And Secondary Output Ports. With ABS 3. Disconnect the primary and secondary brake tubes from the master cylinder. Install plugs at all open brake tube outlets on master cylinder Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 4396 assembly. 4. On vehicles equipped with ABS, clean area where master cylinder attaches to booster using a suitable brake cleaner such as Mopar Brake Parts Cleaner or an equivalent. Master Cylinder Mounting To Vacuum Booster 5. Remove the 2 nuts attaching master cylinder housing to power brake vacuum booster. 6. Slide master cylinder assembly straight out of the power brake vacuum booster. CAUTION: On vehicles equipped with ABS, the master cylinder is used to create the seal for holding vacuum in the power brake vacuum booster. The vacuum seal in the front of the power brake vacuum booster MUST be replaced whenever the master cylinder is removed from the power brake vacuum booster. Removing Seal From Vacuum Booster 7. If vehicle is equipped with ABS, remove vacuum seal located in the front of the power brake vacuum booster. Vacuum seal is removed by carefully inserting a small screw driver between the push rod of the power brake vacuum booster and vacuum seal and prying seal out of power brake vacuum booster. Do not attempt to pry seal out of master cylinder by inserting a tool between seal and power brake vacuum booster. Power Brake Vacuum Booster Check Valve Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 4397 8. Disconnect vacuum hoses from check valve on power brake vacuum booster. Do not remove check valve from power brake vacuum booster. NOTE: If vehicle is equipped with antilock brakes, the Hydraulic Control Unit (HCU) needs to be removed from the vehicle to allow removal of the power brake vacuum booster. Refer to Antilock Brake System Hydraulic Control Unit Service and Repair. Input Rod Retaining Pin 9. Locate the power brake vacuum booster input rod to brake pedal attachment under instrument panel. Position a small screwdriver under the center tang of the retaining clip. CAUTION: Discard retaining clip when removed, it is not to be reused. Replace only with a new retaining clip when assembled. 10. Rotate screwdriver enough to allow retaining clip tang to pass over the end of the brake pedal pin. Power Brake Booster Mounting 11. Remove the 4 nuts attaching the power brake vacuum booster to the dash panel. The nuts are accessible from under the instrument panel in the area of the steering column and brake pedal bracket. 12. Slide power brake vacuum booster forward until mounting studs clear dash panel, then tilt the booster up and to the center of the vehicle to remove. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 4398 Vacuum Brake Booster: Service and Repair Installation PROCEDURE 1. Position power brake booster onto dash panel. Power Brake Booster Mounting 2. Install and torque the 4 power brake vacuum booster mounting nuts to 29 Nm (250 in. lbs.) torque. 3. Using Lubriplate, or equivalent, coat the surface of the brake pedal pin where it contacts the brake vacuum booster input rod. 4. Connect power brake vacuum booster input rod to brake pedal pin and install a NEW retaining clip. Use only a new retainer clip DO NOT USE the old clip. 5. Connect all previously removed vacuum hoses onto power brake vacuum booster check valve. 6. If vehicle is equipped with ABS, install Hydraulic Control Unit HCU. Refer to Antilock Brake System Hydraulic Control Unit Service and Repair. CAUTION: When replacing the power brake vacuum booster on a vehicle equipped with ABS, a NEW vacuum seal MUST be installed in the power brake vacuum booster. Use only the procedure detailed below for installing vacuum seal into power brake vacuum booster. If old vacuum seal came out with master cylinder when it was removed from power brake vacuum booster, be sure it is removed from master cylinder before attempting to install master cylinder into power brake vacuum booster. CAUTION: When lubricating master cylinder push rod, use only Mopar Silicone Dielectric Compound. Using any other type of grease or lubricant on the push rod, will not provide adequate long term lubrication of the push rod. Lubricating Master Cylinder Push Rod 7. Lubricate master cylinder push rod as indicated in only using Mopar Dielectric Grease-And No Substitutes. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 4399 Fig 19 Type 3 Vacuum Seal Installation. Neon Models Equipped With ABS Fig 20 Type 3 Vacuum Seal Seating. Neon Models Equipped With ABS 8. Install vacuum seal on master cylinder push rod as shown with notches on vacuum seal pointing toward master cylinder housing. Then slide vacuum seal onto master push rod until seal is seated against master cylinder housing before installing master cylinder on power brake vacuum booster. CAUTION: If vehicle is equipped with ABS, be sure the old vacuum seal is removed from power brake vacuum booster before attempting to install master cylinder and NEW vacuum seal. If vacuum seal is not removed, refer to Master Cylinder Service and Repair Removal. 9. Position master cylinder on studs of power brake unit, aligning push rod on power brake vacuum booster with master cylinder push rod. 10. Install the 2 master cylinder mounting nuts and torque to 28 Nm (250 in. lbs.) torque. Primary And Secondary Brake Tubes Without ABS Brakes Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 4400 Bleeding Tubes Attached To Non-ABS Master Cylinder 11. Connect brake tubes to master cylinder primary and secondary ports. Torque all tube nuts to 17 Nm (145 in. lbs.) torque. 12. Reconnect wiring connector to fluid level sensor. 13. Adjust stop lamp switch as necessary. 14. Bleed brake system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations System Relay And Pump Motor Relay Box Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Description and Operation > ABS System Relay ABS Main Relay: Description and Operation ABS System Relay CIRCUIT OPERATION The system relay is used for the operation of the Anti Lock Brake (ABS) system. Power for the relay is supplied on the B57 circuit from cavity 57 of the Controller Anti Lock Brake (CAB). Ground for the relay is on the Z1 circuit. This ground is spliced in with the pump motor and terminates at the left headlamp ground. When the system is operating normally power for the contact side of the relay is supplied from the CAB on the B57 circuit. It passes through the relay to the Z1 ground and terminates at the left headlamp ground. If a problem is detected in the system, the contact side of the relay switches from the Z1 to the F12 circuit. This causes the ABS warning lamp in the instrument cluster to illuminate. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Description and Operation > ABS System Relay > Page 4407 ABS Main Relay: Description and Operation ABS System Relays System Relay And Pump Motor Relay Box SYSTEM RELAY The main purpose of the system relay is to put the Antilock Brake System (ABS) into a stand-by mode for ABS operation. The System Relay is energized by the Controller Antilock Brake (CAB) shortly after the ignition switch is turned on. When Energized - by the CAB, the System Relay turns off the ABS warning lamp and provides 12 volts to the CAB. This voltage can then be used by the CAB to energize the Decay Solenoids during ABS braking. When energized, the System Relay also provides the Pump/Motor Relay coil with 12 volts. The ground path to the Pump/Motor Relay is completed by the CAB during ABS braking. When De-energized - the ABS warning lamp is illuminated, voltage to the Decay Solenoids is cut off, and the Pump/Motor Relay is prevented from energizing. Typically, the System Relay is de-energized by the CAB when a fault is detected that requires turning ABS off. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Description and Operation > Description Brake Fluid Pump Relay: Description and Operation Description System Relay And Pump Motor Relay Box PURPOSE Pump/Motor power is supplied by the Pump/Motor Relay. The pump motor relay is also part of the relay box mounted to the Hydraulic Control Unit (HCU). If pump/motor relay replacement is required, it is also only serviced by the replacement of the relay box assembly. FUNCTION Voltage for the 12 volt side of the relay coil is provided by the System Relay. The ground path through the relay coil is completed by the Controller Antilock Brake (CAB) during Antilock Brake System (ABS) braking. The relay contacts are closed when the relay is energized. This provides 12 volts to the pump/motor as needed during ABS braking. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Description and Operation > Description > Page 4412 Brake Fluid Pump Relay: Description and Operation Circuit Operation CIRCUIT OPERATION The Anti Lock Brake (ABS) pump motor relay controls when the pump motor runs. Power for the coil side of the relay is supplied from cavity 47 of the Controller Anti Lock Brake (CAB) on the B47 circuit. This circuit also supplies voltage for the contact side of the system relay The ground side of the coil is controlled by the B116 circuit. Circuit B116 connects to cavity 16 of the CAB connector. Circuit B120 from cavity 20 of the CAB connector powers the ABS pump motor. This circuit is also used as an input to the CAB for pump motor monitoring. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations CAB 60-Way Wiring Harness Connector Controller Antilock Brake The CAB is mounted under the instrument panel behind the drivers side kick panel of the vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4416 Electronic Brake Control Module: Description and Operation Controller Antilock Brake PURPOSE The Controller Antilock Brake (CAB) is a microprocessor based device which monitors the Antilock Brake System (ABS) during normal braking and controls it when in an ABS stop. The CAB is mounted under the instrument panel on the drivers side kick panel. The CAB uses a 60 way electrical connector on the vehicle wiring harness. The power source for the CAB is through the ignition switch in the Run or On position. NOTE: The CAB is not on the Chrysler Collision Detection (CCD) bus. THE PRIMARY FUNCTIONS OF THE CAB - Detect wheel locking tendencies. - Control fluid modulation to the brakes while in ABS mode. - Monitor the system for proper operation. - Provide communication to the DRB scan tool while in diagnostic mode. The CAB Continuously Monitors - the speed of each wheel through the signals generated at the Wheel Speed Sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the CAB commands the Hydraulic Control Unit (HCU) to modulate brake fluid pressure in some or all of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The ABS System Is Constantly Monitored - by the CAB for proper operation. If the CAB detects a fault, it will turn on the Amber ABS Warning Lamp and disable the ABS braking system. The normal Non ABS braking system will remain operational. The CAB Contains A Self-diagnostic Program - which will turn on the Amber ABS Warning Lamp when a ABS system fault is detected. Faults Are Then Stored - in a diagnostic program memory. There are multiple fault messages which may be stored in the CAB and displayed through the DRB. These fault messages will remain in the CAB memory even after the ignition has been turned off. The fault messages can be cleared by using the DRB diagnostics tester, or they will be automatically cleared from the memory after the vehicle is driven approximately 3500 miles. CONTROLLER ANTILOCK BRAKE INPUTS ^ Four wheel speed sensors. ^ Stop lamp switch. ^ Ignition switch. ^ System relay voltage. ^ Ground. ^ Pump/Motor Relay Monitor ^ Diagnostics Communications CONTROLLER ANTILOCK BRAKE OUTPUTS ^ 4 Decay Solenoids ^ ABS warning lamp. ^ System relay actuation. ^ Diagnostic communication. ^ Pump motor relay actuation Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4417 Electronic Brake Control Module: Service and Repair Controller Antilock Brake REMOVE 1. Turn vehicle ignition off. CAB 60-Way Wiring Harness Connector 2. Disconnect the wiring harness 60 way connector from the Controller Antilock Brake Module (CAB). Verify that the vehicle ignition is off before removing the 60 way connector. CAB Bracket To Kick Panel Mounting 3. Remove the 2 controller bracket to drivers side cowl mounting nuts. 4. Remove the CAB from the vehicle. INSTALL 1. Install CAB and mounting bracket on mounting studs located on passenger side kick panel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4418 2. Install the 2 CAB bracket mounting nuts and securely tighten. 3. Install the 60-way wiring harness connector by hand into the 60-way CAB connector, as far as possible. Then use the CAB connector retaining bolt to fully seat wiring harness connector into the CAB. 4. Torque the 60-way connector retaining bolt to 4 Nm (38 inch lbs.). 5. If a new CAB is being has been installed, it must be initialized prior to the vehicle being driven. The CAB is initialized using the DRB Scan Tool and the initializing procedure described upon selecting Bendix ABX-4 Diagnostics. New controllers are programmed to flash the ABS warning lamp until initialized by the installing technician. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Switch <--> [Brake Fluid Level Sensor/Switch] > Component Information > Locations Master Cylinder Fluid Level Sensor Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Switch <--> [Brake Fluid Level Sensor/Switch] > Component Information > Locations > Page 4423 Brake Fluid Level Switch: Service and Repair GENERAL INFORMATION The master cylinder or brake fluid reservoir does not have to be removed from vehicle for replacement of the brake fluid level sensor. Master Cylinder Fluid Level Sensor 1. Remove wiring harness connector from brake fluid reservoir level sensor. Brake Fluid Level Switch Retaining Tabs 2. Compress retaining tabs on end of brake fluid level switch. Removing/Installing Fluid Reservoir Level Switch 3. While compressing retaining tabs, grasp opposite end of brake fluid level switch and pull it out of master cylinder brake fluid reservoir. 4. Correctly align the replacement level switch with its mounting hole in the brake fluid reservoir. Push switch into fluid reservoir until retaining tabs are fully expanded on opposite side of fluid reservoir. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Switch <--> [Brake Fluid Level Sensor/Switch] > Component Information > Locations > Page 4424 5. Install the wiring harness connector onto the brake fluid level switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Description and Operation Braking Sensor/Switch: Description and Operation CIRCUIT OPERATION Circuit L50 is an input to the Controller Anti Lock Brake (CAB). The L50 connects to cavity 13 of the CAB connector. Circuit L50 is spliced in with the stop lamps and is used to provide the CAB with information on when the brakes are being applied. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4432 39 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4433 43 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4434 45 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4435 47 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4436 51 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4437 55 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4438 57 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4439 59 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4440 63 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4441 67 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4442 69 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4443 71 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4444 173 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4445 177 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4446 179 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4447 181 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4448 187 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4449 191 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4450 193 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4451 195 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4452 201 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4453 205 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4454 207 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4455 209 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4456 256 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 4457 Wheel Speed Sensor: Specifications Front Rear Clearance Minimum Clearance 0.014 in 0.016 in Maximum Clearance 0.047 in 0.047 in Runout 0.006 in 0.006 in Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 4458 Wheel Speed Sensor: Service Precautions NOTE: Proper installation of the Wheel Speed Sensor Cables is critical to continued system operation. Be sure that cables are installed, routed and clipped properly. Failure to install speed sensor cables as in the on car service section of this manual, may result in contact with moving parts or over extension of cables, resulting in an open circuit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation Wheel Speed Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION There are four wheel speed sensors, one at each wheel. The sensors use a tone wheel to determine wheel speed. Input to the Controller Anti Lock Brake (CAB) is done on the following circuits. All of these circuits are a twisted pair. B8 and B9 for the left front wheel (cavity 8 and cavity 9). B6 and B7 for the right front wheel (cavity 6 and cavity 7). B3 and B4 for the left rear wheel (cavity 3 and cavity 4). B1 and B2 for the right rear wheel (cavity 1 and cavity 2). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 4461 Wheel Speed Sensor: Description and Operation Wheel Speed Sensors and Tone Wheels Front Wheel Speed Sensor Rear Wheel Speed Sensor With Drum Brakes Rear Wheel Speed Sensor With Rear Disc Brakes One Wheel Speed Sensor (WSS) is located at each wheel and sends a small AC signal to the Controller Antilock Brake (CAB). This signal is generated by magnetic induction created when a toothed sensor ring (tone wheel) passes the stationary magnetic Wheel Speed Sensor. The CAB converts the AC signal generated at each wheel into a digital signal. If a wheel locking tendency is detected by the CAB, it will then modulate hydraulic pressure via the Hydraulic Control Unit (HCU) to prevent the wheel(s) from locking. The front Wheel Speed Sensor is attached to a boss in the steering knuckle. The tone wheel is part of the outboard constant velocity joint. The rear Wheel Speed Sensor on rear drum brake applications is mounted to the rear brake support plate and the rear tone wheel is an integral part of the rear wheel hub and bearing assembly. The rear Wheel Speed Sensor on rear disc brake applications is mounted to the rear disc brake adapter and the rear tone wheel is also an integral part of the rearwheel hub and bearing assembly. The speed sensor air gap on both applications is NOT adjustable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 4462 The four Wheel Speed Sensors are serviced individually. The front Tone Wheels are serviced as an assembly with the outboard constant velocity joint. The rear Tone Wheels are serviced as an assembly with the rear hub and bearing assembly. Correct ABS system operation is dependent on accurate wheel speed signals. The vehicle's wheels and tires must all be the same size and type to generate accurate signals. Variations in wheel and tire size can produce inaccurate wheel speed signals. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Page 4463 Wheel Speed Sensor: Testing and Inspection CAREFUL INSPECTION Carefully inspect tone wheel at the suspected faulty wheel speed sensor for missing, chipped or broken teeth, this can cause erratic speed sensor signals. Tone wheels should show no evidence of contact with the wheel speed sensors. If contact was made, determine cause and correct before replacing the wheel speed sensor. Excessive Runout - of the tonewheel can cause erratic wheel speed sensor signals. Refer to Tone-wheel Runout under Specification. Replace drive shaft assembly or rear hub/bearing assembly if tonewheel runout exceeds the specification. Inspect For Looseness - on their mounting surfaces. Tone wheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Check the wheel speed sensor head alignment to the tone wheel. Also check the gap between the speed sensor head and the tone wheel to ensure it is at specification. See: Specifications Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front Speed Sensor Cable To Wiring Herness Connection Front Wheel Speed Sensor Attaching Bolt Front Wheel Speed Sensor Cable Routing NOTE: Proper installation of the Wheel Speed Sensor Cables is critical to continued system operation. Be sure that cables are installed, routed and clipped properly. Failure to install speed sensor cables as in the on car service section of this manual, may result in contact with moving parts or over extension of cables, resulting in an open circuit. REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. 3. Unplug speed sensor cable connector from vehicle wiring harness. Remove clip attaching speed sensor cable connector to vehicle body. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4466 4. Remove wheel speed sensor head to steering knuckle attaching bolt. 5. Carefully, remove sensor head from steering knuckle. If the sensor has seized, due to corrosion, DO NOT USE PLIERS ON SENSOR HEAD. Use a hammer and a punch and tap edge of sensor ear, rocking the sensor side to side until free. 6. Remove the speed sensor cable assembly grommets from the retaining bracket. Remove speed sensor cable routing clip from the frame of the vehicle. INSTALL 1. Connect the wheel speed sensor cable connector to the vehicle wiring harness. 2. Install the speed sensor cable assembly grommets into the retaining bracket. Install speed sensor cable routing clip onto the frame of the vehicle. 3. Install wheel speed sensor to steering knuckle attaching screw. Torque the attaching screw to 7 Nm (60 inch lbs.) 4. Install the wheel and tire assembly on vehicle. 5. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4467 Wheel Speed Sensor: Service and Repair Rear Rear Speed Sensor Connection To Vehicle Wiring Harness Speed Sensor Head Mounting And Cable Routing NOTE: Proper installation of the Wheel Speed Sensor Cables is critical to continued system operation. Be sure that cables are installed, routed and clipped properly. Failure to install speed sensor cables as in the on car service section of this manual, may result in contact with moving parts or over extension of cables, resulting in an open circuit. REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. 3. Unplug speed sensor cable connector from vehicle wiring harness. Remove clip attaching speed sensor cable connector to vehicle body. 4. Remove the speed sensor cable routing bracket from under rear brake flex hose mounting bracket. Then remove the speed sensor cable from the routing clips on the rear brake flex hose and chassis brake tube. 5. Remove bolt attaching the rear wheel speed sensor to the disc brake adapter. The remove bolt attaching speed sensor cable routing bracket to rear strut assembly. 6. Remove speed sensor head from the disc brake adapter. If the speed sensor head has seized in the adapter, DO NOT USE PLIERS ON SENSOR HEAD. INSTALL 1. Install wheel speed sensor head into disc brake adapter. 2. Install wheel speed sensor attaching bolt. Tighten the attaching bolt to a torque of 7 Nm (60 inch lbs.) 3. Install the brake flex hose and wheel speed sensor cable routing bracket on the rear strut bracket. 4. Install wheel speed sensor cable into the routing clips on the rear brake flex hose and chassis brake tube. 5. Plug speed sensor cable connector into vehicle wiring harness. Install clip attaching speed sensor cable connector to vehicle body. 6. Install the tire and wheel assembly on vehicle. 7. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Service Precautions Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Service Precautions > Page 4473 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature. This temperature data, along with data from monitored line voltage, is used by the (PCM) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Battery Temperature Sensor The sensor is located forward of the vehicle battery, and is attached to the battery tray. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to Powertrain Management/Computer and Controls/Testing and Inspection. 1. The sensor is located under the battery and is attached to the battery tray. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25 °C (75-80 °F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) Ohms should be observed. 5. If reading is above or below the specification, replace the sensor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 4476 Battery Temperature Sensor: Service and Repair REMOVE 1. Make sure ignition switch is in OFF position and all accessories are OFF. Disconnect Battery Negative Cable 2. Remove battery negative cable first then the positive cable. Battery Thermoguard 3. Remove battery thermoguard. WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN. Air Inlet Tube Pull Strap Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 4477 4. Remove temperature sensor mounting nut from battery tray. Battery Temperature Sensor Connector 5. Disconnect sensor wire connector. INSTALL - For installation reverse above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation The clutch pedal position switch functions as a safety interlock device. It prevents possible engine cranking with the clutch engaged. The clutch pedal position switch is wired in series between the starter relay coil and the ignition switch. The clutch pedal position switch is mounted to a bracket located behind the clutch pedal. The switch is held in place by four plastic wing tabs. The clutch pedal position switch IS NOT adjustable. The pedal blade contacts the switch in the down position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation > Page 4481 Clutch Switch: Testing and Inspection ELECTRICAL TEST Disconnect clutch pedal position switch harness from instrument panel wiring harness. Using an ohmmeter, check for continuity between the two terminals in the connector on the switch harness. There should be no continuity between the terminals when the switch is in its normal (fully extended) position. When the switch is depressed more than 1.25 mm (0.050 inch), the ohmmeter should show continuity (zero ohms). If ohmmeter readings do not fall within these ranges, the switch is defective, and must be replaced. MECHANICAL TEST With the park brake set and the vehicle IN NEUTRAL, turn the key to the start position. The vehicle should not crank. If the vehicle cranks, the switch is defective (shorted out) and must be replaced. If the vehicle does not crank proceed to the next step. WARNING: Before performing this step, be sure that the area in front of the vehicle is clear of obstructions and people. Vehicle may move when performing this test. With the park brake set and the vehicle IN GEAR, turn the key to the start position and hold it there. Slowly depress the clutch pedal and feel for any vehicle motion when the starter is energized. If there is no motion the switch is working properly. If motion is felt, check to see if the switch is making contact when the pedal is between 25 mm (1.0 inch) and 6 mm (0.25 inch) from the floor. If this condition is met, then the problem is either the clutch or the self-adjusting cable. If this condition is not met, then the switch mounting tab on the brake bracket is bent, and the brake bracket must be replaced. If vehicle will not crank, even with clutch pedal pressed to the floor, refer to illustrated chart. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation > Page 4482 Clutch Switch: Adjustments The clutch pedal position switch is mounted to a bracket located behind the clutch pedal. The switch is held in place by four plastic wing tabs. The clutch pedal position switch IS NOT adjustable. The pedal blade contacts the switch in the down position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation > Page 4483 Clutch Switch: Service and Repair NOTES: ^ The clutch pedal position switch is mounted to a bracket located behind the clutch pedal. The switch is held in place by four plastic wing tabs. ^ The clutch pedal position switch IS NOT adjustable. The pedal blade contacts the switch in the down position. REMOVAL 1. Disconnect electrical harness to switch connector. 2. Depress wing tabs on switch and push switch out of mounting bracket. Then slide wires through slot in bracket. INSTALLATION 1. Slide switch wires through slot in switch bracket. 2. Line up switch tab with slot in switch bracket and push switch into position. Do not pull on the switch wires to seat switch into bracket, switch damage may occur. 3. Attach switch wiring harness to vehicle wiring harness. 4. After installation, the switch must be checked for proper operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation SYSTEM OPERATION Ignition Lock Cylinder Detents The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detents: - Accessory - Off (lock) - Unlock - On/Run - Start Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4488 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Detentes The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detentes: Accessory - Off (lock) - Unlock - On/Run - Start REMOVAL 1. Disconnect negative cable from battery. 2. Place key cylinder in RUN position. - Through the hole in the lower shroud, depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. - Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. - To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. - Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Connect negative cable to battery Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 34 Nm (25 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 4492 Neutral Safety Switch: Testing and Inspection The park/neutral starting switch is the center terminal of the three terminal switch. It provides ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 4493 Neutral Safety Switch: Service and Repair REMOVAL Unscrew switch from transaxle case allowing fluid to drain into a container. Move selector lever to PARK, then to NEUTRAL position, and inspect to see the switch operating lever fingers are centered in switch opening. INSTALLATION 1. Screw the switch with a new seal into transaxle case and tighten to 33 Nm (24 ft. lbs.). Retest switch with the test lamp. 2. Add fluid to transaxle to bring up to proper level. 3. The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 4. To test switch, remove wiring connector from switch and test for continuity between the two outside pins. 5. Continuity should exist only with transaxle in REVERSE position. 6. No continuity should exist from either pin to the case. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Component Locations Power Distribution Center (Top) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Component Locations > Page 4499 Auto Shutdown Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4500 Starter Relay: Diagrams Power Distribution Center (Bottom) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4501 Power Distribution Center (Top) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4502 Starter Relay: Testing and Inspection WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK POSITION/NEUTRAL WITH THE PARKING BRAKE APPLIED Relay Test The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. Remove the starter relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 Ohms. If OK, go to Step 3. If not OK, replace the faulty relay 3. Connect a battery B+ lead to terminals 86 and a ground lead to terminal 85 to energize the relay The relay should click. Also test for continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, refer to Relay Circuit Test procedure. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. It is energized when the ignition switch is held in the Start position. On vehicles with a manual transmission, the clutch pedal must be fully depressed for this test. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position, and no voltage when the ignition switch is released to the On position. If OK, go to Step 5. If not OK with an automatic transmission, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, see the Ignition Switch Test procedure. If not OK with a manual transmission, check the circuit between the relay and the clutch pedal position switch for an open or a short. If the circuit is OK, see the Clutch Pedal Position Switch/Brake pedal Switch/Sensor Test procedure. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with an automatic transmission, it is grounded through the park/neutral position switch only when the gearshift selector lever is in the Park or Neutral positions. On vehicles with a manual transmission, it is grounded at all times. Check for continuity to ground at the cavity for relay terminal 85. If not OK with an automatic transmission, check for an open or short circuit to the park/neutral position switch and repair, if required. If the circuit is OK, see the Park/Neutral Position Switch/Neutral Safety Switch Test procedure. If not OK with a manual transmission, repair the circuit to ground as required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Service Precautions Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Service Precautions > Page 4507 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature. This temperature data, along with data from monitored line voltage, is used by the (PCM) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Battery Temperature Sensor The sensor is located forward of the vehicle battery, and is attached to the battery tray. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to Powertrain Management/Computer and Controls/Testing and Inspection. 1. The sensor is located under the battery and is attached to the battery tray. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25 °C (75-80 °F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) Ohms should be observed. 5. If reading is above or below the specification, replace the sensor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 4510 Battery Temperature Sensor: Service and Repair REMOVE 1. Make sure ignition switch is in OFF position and all accessories are OFF. Disconnect Battery Negative Cable 2. Remove battery negative cable first then the positive cable. Battery Thermoguard 3. Remove battery thermoguard. WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN. Air Inlet Tube Pull Strap Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 4511 4. Remove temperature sensor mounting nut from battery tray. Battery Temperature Sensor Connector 5. Disconnect sensor wire connector. INSTALL - For installation reverse above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Electrical Specifications Generator: Electrical Specifications Voltage Powertrain Control Module (PCM) regulates charging system voltage by controlling the generator field source (+) circuit. The voltage range is 12.9 to 15.0 volts Rated Amps Rated SAE Amps ................................................................................................................................. ..................................................................... 83 amps Minimum Test Amps ............................................................................................................................ ..................................................................... 75 amps Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Electrical Specifications > Page 4517 Generator: Mechanical Specifications DESCRIPTION = TORQUE Battery Terminal Nut = 9 N.m (75 in. lbs.) Battery Hold Down Clamp Bolt = 9 N.m (75 in. lbs.) Generator Mounting Bolt = 54 N.m (40 ft. lbs.) Generator Pivot Bolt = 54 N.m (40 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Page 4518 Generator: Description and Operation SYSTEM OPERATION The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced. As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. Once the generator begins producing sufficient current, it also provides the current needed to energize the rotor. The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified DC current is delivered to the vehicle electrical system through the generator, battery, and ground terminals. Noise emitting from the generator may be caused by: Worn, loose or defective bearings - Loose or defective drive pulley - Incorrect, worn, damaged or misadjusted drive belt - Loose mounting bolts - Misaligned drive pulley - Defective stator or diode Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Page 4519 Generator: Service and Repair REMOVE Removal/Installation Of Battery Cables 1. Disconnect battery negative cable. 2. Loosen but DO NOT remove the generator adjustment nut. 3. Raise vehicle with front wheels turned fully to the right. 4. Remove the plastic lower splash shield. Generator Rear View 5. Disconnect the generator field circuit wiring connector. Squeeze locking tab to release. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Page 4520 Wire Terminal Connection 6. Remove the B+ terminal nut and wire. Generator Front View Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Page 4521 Generator Rear View 7. Loosen pivot bolt, but do not remove. 8. Remove the generator drive belt. The generator spill shield does not need to be removed. 9. Remove three mounting pivot bracket bolts. 10. Remove pivot bolt and bracket. 11. Holding the generator in one hand, remove adjustment nut and slide the generator off the T-bolt. The T-bolt does not need to be removed. 12. Lower the generator and remove through the wheel well. INSTALL 1. For installation, reverse above procedures. The generator field connector has a locking tab and will snap when fully installed. Tighten all fasteners to the proper torque. Refer to Starting and Charging/Battery/Torque Specifications chart. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Description and Operation Voltage Regulator: Description and Operation SYSTEM OPERATION The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. Operation: The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage and battery temperature. It then compensates and regulates generator current output accordingly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation The clutch pedal position switch functions as a safety interlock device. It prevents possible engine cranking with the clutch engaged. The clutch pedal position switch is wired in series between the starter relay coil and the ignition switch. The clutch pedal position switch is mounted to a bracket located behind the clutch pedal. The switch is held in place by four plastic wing tabs. The clutch pedal position switch IS NOT adjustable. The pedal blade contacts the switch in the down position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Description and Operation > Page 4529 Clutch Switch: Testing and Inspection ELECTRICAL TEST Disconnect clutch pedal position switch harness from instrument panel wiring harness. Using an ohmmeter, check for continuity between the two terminals in the connector on the switch harness. There should be no continuity between the terminals when the switch is in its normal (fully extended) position. When the switch is depressed more than 1.25 mm (0.050 inch), the ohmmeter should show continuity (zero ohms). If ohmmeter readings do not fall within these ranges, the switch is defective, and must be replaced. MECHANICAL TEST With the park brake set and the vehicle IN NEUTRAL, turn the key to the start position. The vehicle should not crank. If the vehicle cranks, the switch is defective (shorted out) and must be replaced. If the vehicle does not crank proceed to the next step. WARNING: Before performing this step, be sure that the area in front of the vehicle is clear of obstructions and people. Vehicle may move when performing this test. With the park brake set and the vehicle IN GEAR, turn the key to the start position and hold it there. Slowly depress the clutch pedal and feel for any vehicle motion when the starter is energized. If there is no motion the switch is working properly. If motion is felt, check to see if the switch is making contact when the pedal is between 25 mm (1.0 inch) and 6 mm (0.25 inch) from the floor. If this condition is met, then the problem is either the clutch or the self-adjusting cable. If this condition is not met, then the switch mounting tab on the brake bracket is bent, and the brake bracket must be replaced. If vehicle will not crank, even with clutch pedal pressed to the floor, refer to illustrated chart. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Description and Operation > Page 4530 Clutch Switch: Adjustments The clutch pedal position switch is mounted to a bracket located behind the clutch pedal. The switch is held in place by four plastic wing tabs. The clutch pedal position switch IS NOT adjustable. The pedal blade contacts the switch in the down position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Description and Operation > Page 4531 Clutch Switch: Service and Repair NOTES: ^ The clutch pedal position switch is mounted to a bracket located behind the clutch pedal. The switch is held in place by four plastic wing tabs. ^ The clutch pedal position switch IS NOT adjustable. The pedal blade contacts the switch in the down position. REMOVAL 1. Disconnect electrical harness to switch connector. 2. Depress wing tabs on switch and push switch out of mounting bracket. Then slide wires through slot in bracket. INSTALLATION 1. Slide switch wires through slot in switch bracket. 2. Line up switch tab with slot in switch bracket and push switch into position. Do not pull on the switch wires to seat switch into bracket, switch damage may occur. 3. Attach switch wiring harness to vehicle wiring harness. 4. After installation, the switch must be checked for proper operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation SYSTEM OPERATION Ignition Lock Cylinder Detents The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detents: - Accessory - Off (lock) - Unlock - On/Run - Start Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4536 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Detentes The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detentes: Accessory - Off (lock) - Unlock - On/Run - Start REMOVAL 1. Disconnect negative cable from battery. 2. Place key cylinder in RUN position. - Through the hole in the lower shroud, depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. - Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. - To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. - Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Connect negative cable to battery Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 34 Nm (25 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Specifications > Page 4540 Neutral Safety Switch: Testing and Inspection The park/neutral starting switch is the center terminal of the three terminal switch. It provides ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Specifications > Page 4541 Neutral Safety Switch: Service and Repair REMOVAL Unscrew switch from transaxle case allowing fluid to drain into a container. Move selector lever to PARK, then to NEUTRAL position, and inspect to see the switch operating lever fingers are centered in switch opening. INSTALLATION 1. Screw the switch with a new seal into transaxle case and tighten to 33 Nm (24 ft. lbs.). Retest switch with the test lamp. 2. Add fluid to transaxle to bring up to proper level. 3. The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 4. To test switch, remove wiring connector from switch and test for continuity between the two outside pins. 5. Continuity should exist only with transaxle in REVERSE position. 6. No continuity should exist from either pin to the case. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair Starter Motor: Service and Repair REMOVE Battery Cable Removal And Installation 1. Disconnect battery negative cable. 2. Raise vehicle. 3. Vehicles equipped with A/C: a. Using a floor jack or jack stand, support the engine and transmission assembly so they will not rotate. Front Engine Mount Bolt Removal b. Remove the front engine mount bolt from the insulator and front crossmember mounting bracket. c. Lower the front of the engine, rotate the engine forward, allowing easier removal of starter motor. 4. For easier servicing, do not remove the wiring from starter at this time. Starter Removal Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Page 4545 5. Remove two bolts attaching starter to transmission housing. 6. Remove starter/starter solenoid assembly from transmission housing. Position the starter to gain access to the wiring connectors. Wire Connection 7. Remove the battery positive cable nut and remove the battery positive and generator output wire from the starter. 8. Disconnect push-on solenoid connector. 9. Position the starter vertically such that the pinion end faces downward. 10. Remove the starter through the bottom of the vehicle. Move aside A/C plumbing as necessary. INSTALL 1. Clean corrosion/dirt from the cable and wire terminals before installing wiring to the solenoid. 2. Connect the battery positive and generator output wire to the starter solenoid post. CAUTION: It is critical that the generator output terminal be connected to the battery positive terminal of the starter solenoid, for proper operation of the charging and cranking systems. 3. Connect the push-on solenoid connector. 4. Position the starter face into transmission housing. Support starter in pilot and start the top bolt. 5. Attach ground cable to lower mounting bolt and start bolt. 6. Ensure the proper starter alignment before tightening the starter mounting bolts to 54 N.m (40 ft. lbs.) torque. 7. Vehicles equipped with A/C: a. Using a floor jack or jack stand, raise the engine and transmission assembly to the original position. b. Install the front engine mount bolt through the insulator and front crossmember mounting bracket. c. Tighten bolt to 54 N.m (40 ft. lbs.) torque. 8. Lower vehicle and connect battery cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Component Locations Power Distribution Center (Top) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Component Locations > Page 4550 Auto Shutdown Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4551 Starter Relay: Diagrams Power Distribution Center (Bottom) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4552 Power Distribution Center (Top) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4553 Starter Relay: Testing and Inspection WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK POSITION/NEUTRAL WITH THE PARKING BRAKE APPLIED Relay Test The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. Remove the starter relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 Ohms. If OK, go to Step 3. If not OK, replace the faulty relay 3. Connect a battery B+ lead to terminals 86 and a ground lead to terminal 85 to energize the relay The relay should click. Also test for continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, refer to Relay Circuit Test procedure. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. It is energized when the ignition switch is held in the Start position. On vehicles with a manual transmission, the clutch pedal must be fully depressed for this test. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position, and no voltage when the ignition switch is released to the On position. If OK, go to Step 5. If not OK with an automatic transmission, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, see the Ignition Switch Test procedure. If not OK with a manual transmission, check the circuit between the relay and the clutch pedal position switch for an open or a short. If the circuit is OK, see the Clutch Pedal Position Switch/Brake pedal Switch/Sensor Test procedure. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with an automatic transmission, it is grounded through the park/neutral position switch only when the gearshift selector lever is in the Park or Neutral positions. On vehicles with a manual transmission, it is grounded at all times. Check for continuity to ground at the cavity for relay terminal 85. If not OK with an automatic transmission, check for an open or short circuit to the park/neutral position switch and repair, if required. If the circuit is OK, see the Park/Neutral Position Switch/Neutral Safety Switch Test procedure. If not OK with a manual transmission, repair the circuit to ground as required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Testing and Inspection Starter Solenoid: Testing and Inspection WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK POSITION WITH THE PARKING BRAKE APPLIED 1. Verify battery condition. Battery must be in good condition with a full charge before performing any starter tests. Refer to Starting and Charging /Battery/Battery Tests. 2. Perform Starter Solenoid test BEFORE performing the starter relay test. 3. Raise the vehicle. 4. Perform a visual inspection of the starter/ starter solenoid for corrosion, loose connections or faulty wiring. 5. Lower the vehicle. 6. Locate and remove the starter relay from the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. 7. Connect a remote starter switch or a jumper wire between the remote battery positive post and terminal 87 of the starter relay connector. a. If engine cranks, starter/starter solenoid is good. Go to the Starter Relay Test. b. If engine does not or solenoid chatters, check wiring and connectors from starter relay to starter solenoid for loose or corroded connections. Particularly at starter terminals. c. Repeat test. If engine still fails to crank properly, trouble is within starter or starter mounted solenoid, and replace starter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats Technical Service Bulletin # 07-04-98 Date: 980417 Cooling System - Fan ON Continuously/Overheats NO: 07-04-98 GROUP: Cooling DATE: Apr. 17, 1998 SUBJECT: Vehicle Overheats (Radiator Fan Inoperative) Or Radiator Fan Runs Continuously THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-97 DATED FEBRUARY 20, 1998 WHICH SHOULD BE NOTED IN THE 1997 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-98004). THE REVISION PROVIDES A NEW PART NUMBER FOR THE RADIATOR FAN RELAY. THE CHANGE IS HIGHLIGHTED WITH ASTERISKS. MODELS: 1997 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT AT TOLUCA ASSEMBLY PRIOR TO SEPTEMBER 11, 1997 (MDH 0911XX). TOLUCA ASSEMBLY IS DESIGNATED BY A "T" IN THE ELEVENTH POSITION OF THE VEHICLE IDENTIFICATION NUMBER. SYMPTOM/CONDITION: Vehicle overheats or radiator fan continues to run. DIAGNOSIS: Actuate the radiator fan relay using the DRB III. If the radiator fan does not come on or fan runs continuously, perform the Repair Procedure. PARTS REQUIRED: 1 05293157AA Jumper Wire With Diode, Radiator Fan **1 04707286 Relay, Radiator Fan** 2 06015756 Tie Strap POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-12-92 0.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves installing a radiator fan jumper wire assembly into the headlamp and dash wiring harness, and replacing the solid state relay. 1. Raise the hood and disconnect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 4566 2. Raise the vehicle on a suitable hoist. 3. Locate the left (driver's side) black fan motor connector. Retract the red latch on the two-way female connector, depress the thumb latch, and disconnect the connector from the fan (Figure 1). If the wiring to the fan motor is clipped into the fan support, gently pry it out of the hole so the fan is not damaged. 4. Pry out the two christmas tree type retainers located on the lower radiator enclosure reinforcement. 5. Install the jumper wire assembly (p/n 052931 57AA) between the radiator fan and the headlamp and dash harness: A. Attach the black two-way male connector with the clip into the outboard hole, so the connector faces outboard toward the left side of the vehicle. Attach the second clip into the inboard hole of the lower reinforcement that the original wiring came out of (Figure 2). B. Connect the original two-way black connector to the new mating connector installed in the previous step and slide the red latch into the locked position. 6. Connect the two-way female black connector on the new jumper assembly to the fan connector and slide the red latch into the locked position. If the original wiring to the fan was clipped into the fan support, snap the new clip on the jumper into the same hole. 7. Bundle the excess original fan wiring and tie strap to the main bundle of vehicle wiring in the front left corner in two places. NOTE: ENSURE THAT THE WIRING BUNDLE IS SECURE AND DOES NOT INTERFERE WITH ANY OTHER COMPONENTS. 8. The solid state fan relay is located on the left front rail. Retract the red latch on the black four-way connector and disconnect from the solid state fan relay. 9. Remove the two screws that secure the relay to the side of the left front rail and remove the relay. 10. Install the new solid state fan relay ** (p/n 04707286)** and locate the index pin on the relay into the locator hole in the rail. Secure with the two screws and torque to 5 N.m (45 in.lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 4567 11. Connect the four way connector and slide the red latch into the locked position. 12. Lower the vehicle and connect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Other Service Bulletins for Diode: > 232497 > May > 97 > Customer Interest for Diode: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats Technical Service Bulletin # 07-04-98 Date: 980417 Cooling System - Fan ON Continuously/Overheats NO: 07-04-98 GROUP: Cooling DATE: Apr. 17, 1998 SUBJECT: Vehicle Overheats (Radiator Fan Inoperative) Or Radiator Fan Runs Continuously THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-97 DATED FEBRUARY 20, 1998 WHICH SHOULD BE NOTED IN THE 1997 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-98004). THE REVISION PROVIDES A NEW PART NUMBER FOR THE RADIATOR FAN RELAY. THE CHANGE IS HIGHLIGHTED WITH ASTERISKS. MODELS: 1997 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT AT TOLUCA ASSEMBLY PRIOR TO SEPTEMBER 11, 1997 (MDH 0911XX). TOLUCA ASSEMBLY IS DESIGNATED BY A "T" IN THE ELEVENTH POSITION OF THE VEHICLE IDENTIFICATION NUMBER. SYMPTOM/CONDITION: Vehicle overheats or radiator fan continues to run. DIAGNOSIS: Actuate the radiator fan relay using the DRB III. If the radiator fan does not come on or fan runs continuously, perform the Repair Procedure. PARTS REQUIRED: 1 05293157AA Jumper Wire With Diode, Radiator Fan **1 04707286 Relay, Radiator Fan** 2 06015756 Tie Strap POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-12-92 0.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves installing a radiator fan jumper wire assembly into the headlamp and dash wiring harness, and replacing the solid state relay. 1. Raise the hood and disconnect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Other Service Bulletins for Diode: > 232497 > May > 97 > Customer Interest for Diode: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 4577 2. Raise the vehicle on a suitable hoist. 3. Locate the left (driver's side) black fan motor connector. Retract the red latch on the two-way female connector, depress the thumb latch, and disconnect the connector from the fan (Figure 1). If the wiring to the fan motor is clipped into the fan support, gently pry it out of the hole so the fan is not damaged. 4. Pry out the two christmas tree type retainers located on the lower radiator enclosure reinforcement. 5. Install the jumper wire assembly (p/n 052931 57AA) between the radiator fan and the headlamp and dash harness: A. Attach the black two-way male connector with the clip into the outboard hole, so the connector faces outboard toward the left side of the vehicle. Attach the second clip into the inboard hole of the lower reinforcement that the original wiring came out of (Figure 2). B. Connect the original two-way black connector to the new mating connector installed in the previous step and slide the red latch into the locked position. 6. Connect the two-way female black connector on the new jumper assembly to the fan connector and slide the red latch into the locked position. If the original wiring to the fan was clipped into the fan support, snap the new clip on the jumper into the same hole. 7. Bundle the excess original fan wiring and tie strap to the main bundle of vehicle wiring in the front left corner in two places. NOTE: ENSURE THAT THE WIRING BUNDLE IS SECURE AND DOES NOT INTERFERE WITH ANY OTHER COMPONENTS. 8. The solid state fan relay is located on the left front rail. Retract the red latch on the black four-way connector and disconnect from the solid state fan relay. 9. Remove the two screws that secure the relay to the side of the left front rail and remove the relay. 10. Install the new solid state fan relay ** (p/n 04707286)** and locate the index pin on the relay into the locator hole in the rail. Secure with the two screws and torque to 5 N.m (45 in.lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Other Service Bulletins for Diode: > 232497 > May > 97 > Customer Interest for Diode: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 4578 11. Connect the four way connector and slide the red latch into the locked position. 12. Lower the vehicle and connect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Other Service Bulletins for Diode: > Page 4579 Stabilizer Bushing: Testing and Inspection Inspect for broken or distorted sway bar bushings, bushing retainers, and worn or damaged sway bar to strut attaching links. If sway bar to front suspension cradle bushing replacement is required, bushing can be removed from sway bar by opening slit and peeling bushing off sway bar. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations Power Distribution Center: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Page 4583 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions Power Distribution Center: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4586 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4587 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4588 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4589 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4590 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4591 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4592 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4593 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4594 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4595 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4596 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4597 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4598 Power Distribution Center: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4599 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4600 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4601 Power Distribution Center: Connector Views Power Distribution Center (Bottom) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4602 Power Distribution Center (Top) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4603 Power Distribution Center: Electrical Diagrams Power Distribution Power Distribution (Part 1 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4604 Power Distribution (Part 2 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4605 Power Distribution (Part 3 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4606 Power Distribution (Part 4 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4607 Power Distribution (Part 5 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4608 Power Distribution (Part 6 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4609 Power Distribution (Part 7 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4610 Power Distribution (Part 8 Of 8) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Ground Distribution Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4611 Ground Distribution (Part 1 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4612 Ground Distribution (Part 2 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4613 Ground Distribution (Part 3 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4614 Ground Distribution (Part 4 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4615 Ground Distribution (Part 5 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4616 Ground Distribution (Part 6 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4617 Ground Distribution (Part 7 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4618 Ground Distribution (Part 8 Of 8) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations Fuse: Locations Fuse Locations Fuse Locations Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4626 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4627 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4628 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4629 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4630 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4631 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4632 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4633 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4634 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4635 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4636 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4637 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4638 Fuse Block: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4639 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4640 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4641 Fuse Block: Connector Views Fuse Block (Part 1 Of 2) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4642 Fuse Block (Part 2 Of 2) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4643 Fuse Block: Electrical Diagrams Fuse Block (Part 1 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4644 Fuse Block (Part 2 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4645 Fuse Block (Part 3 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4646 Fuse Block (Part 4 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4647 Fuse Block (Part 5 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4648 Fuse Block (Part 6 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4649 Fuse Block (Part 7 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4650 Fuse Block (Part 8 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4651 Fuse Block (Part 9 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4652 Fuse Block (Part 10 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4653 Fuse Block (Part 11 Of 11) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Diagram Connector Pinout Revisions Multiple Junction Connector: Technical Service Bulletins Electrical - Wiring Diagram Connector Pinout Revisions NUMBER: 26-10-96C GROUP: Miscellaneous DATE: October, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Neon - Publication Number 81-270-7025 DESCRIPTION OF CHANGES Wiring diagram revisions to the connector pin-outs Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Diagram Connector Pinout Revisions > Page 4658 8W-43-3 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Diagram Connector Pinout Revisions > Page 4659 8W-80-5 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Diagram Connector Pinout Revisions > Page 4660 8W-80-7 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats Technical Service Bulletin # 07-04-98 Date: 980417 Cooling System - Fan ON Continuously/Overheats NO: 07-04-98 GROUP: Cooling DATE: Apr. 17, 1998 SUBJECT: Vehicle Overheats (Radiator Fan Inoperative) Or Radiator Fan Runs Continuously THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-97 DATED FEBRUARY 20, 1998 WHICH SHOULD BE NOTED IN THE 1997 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-98004). THE REVISION PROVIDES A NEW PART NUMBER FOR THE RADIATOR FAN RELAY. THE CHANGE IS HIGHLIGHTED WITH ASTERISKS. MODELS: 1997 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT AT TOLUCA ASSEMBLY PRIOR TO SEPTEMBER 11, 1997 (MDH 0911XX). TOLUCA ASSEMBLY IS DESIGNATED BY A "T" IN THE ELEVENTH POSITION OF THE VEHICLE IDENTIFICATION NUMBER. SYMPTOM/CONDITION: Vehicle overheats or radiator fan continues to run. DIAGNOSIS: Actuate the radiator fan relay using the DRB III. If the radiator fan does not come on or fan runs continuously, perform the Repair Procedure. PARTS REQUIRED: 1 05293157AA Jumper Wire With Diode, Radiator Fan **1 04707286 Relay, Radiator Fan** 2 06015756 Tie Strap POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-12-92 0.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves installing a radiator fan jumper wire assembly into the headlamp and dash wiring harness, and replacing the solid state relay. 1. Raise the hood and disconnect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 4670 2. Raise the vehicle on a suitable hoist. 3. Locate the left (driver's side) black fan motor connector. Retract the red latch on the two-way female connector, depress the thumb latch, and disconnect the connector from the fan (Figure 1). If the wiring to the fan motor is clipped into the fan support, gently pry it out of the hole so the fan is not damaged. 4. Pry out the two christmas tree type retainers located on the lower radiator enclosure reinforcement. 5. Install the jumper wire assembly (p/n 052931 57AA) between the radiator fan and the headlamp and dash harness: A. Attach the black two-way male connector with the clip into the outboard hole, so the connector faces outboard toward the left side of the vehicle. Attach the second clip into the inboard hole of the lower reinforcement that the original wiring came out of (Figure 2). B. Connect the original two-way black connector to the new mating connector installed in the previous step and slide the red latch into the locked position. 6. Connect the two-way female black connector on the new jumper assembly to the fan connector and slide the red latch into the locked position. If the original wiring to the fan was clipped into the fan support, snap the new clip on the jumper into the same hole. 7. Bundle the excess original fan wiring and tie strap to the main bundle of vehicle wiring in the front left corner in two places. NOTE: ENSURE THAT THE WIRING BUNDLE IS SECURE AND DOES NOT INTERFERE WITH ANY OTHER COMPONENTS. 8. The solid state fan relay is located on the left front rail. Retract the red latch on the black four-way connector and disconnect from the solid state fan relay. 9. Remove the two screws that secure the relay to the side of the left front rail and remove the relay. 10. Install the new solid state fan relay ** (p/n 04707286)** and locate the index pin on the relay into the locator hole in the rail. Secure with the two screws and torque to 5 N.m (45 in.lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 4671 11. Connect the four way connector and slide the red latch into the locked position. 12. Lower the vehicle and connect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Component Information > Service Precautions Parking Brake Cable: Service Precautions WARNING: WHEN REPAIRS TO THE PARK BRAKE HAND LEVER ASSEMBLY OR CABLES IS REQUIRED, THE AUTO ADJUSTER MUST BE PRELOADED AND LOCKED OUT. NOTE: Remove only one rear park brake cable from rear brakes at a time. Failure to do so will result in high efforts required to connect park brake cables to equalizer or park brake lever at rear wheel brakes. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Component Information > Service and Repair > Cable Removal Parking Brake Cable: Service and Repair Cable Removal NOTE: Remove only one rear park brake cable from rear brakes at a time. Failure to do so will result in high efforts required to connect park brake cables to equalizer or park brake lever at rear wheel brakes. PROCEDURE Attaching Screws At Rear Of Center Console With Out Arm Rest Attaching Screws At Rear Of Center Console With Arm Rest 1. Remove screws attaching rear of center console assembly to floor pan of vehicle. Attaching Screws At Front Of Center Console 2. Remove the 2 screws located in cup holders attaching front of center console to console bracket. 3. Raise park brake lever as high as it will go for the clearance required to remove the center console. 4. Remove center console assembly from vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Component Information > Service and Repair > Cable Removal > Page 4676 WARNING: WHEN REPAIRS TO THE PARK BRAKE HAND LEVER ASSEMBLY OR CABLES IS REQUIRED, THE AUTO ADJUSTER MUST BE PRELOADED AND LOCKED OUT. 5. Lower park brake lever handle. Locking Pin Installed In Park Brake Lever 6. Grasp park lever output cable by hand and pull rearward. Continue pulling on cable until a 3/16 in. drill bit can be inserted into handle and sector gear of park brake mechanism. This will lock the park brake mechanism and take tension off park brake cables. Park Brake Cables At Equalizer 7. Remove rear park brake cables from the park brake cable equalizer. 8. Remove rear seat cushion from vehicle. Rear Door Sill Scuff Plates Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Component Information > Service and Repair > Cable Removal > Page 4677 9. Remove scuff plates from right and left rear door sills. Scuff plates are attached to door sills using clips on bottom of scuff plates. Remove by carefully prying scuff plate retaining clips out of door sills. 10. Fold rear carpeting forward to expose park brake cables. Compressing Park Brake Cable Retaining Tabs 11. Install the box end of a 1/2 in. wrench over the park brake cable retainer as indicated. This will compress tabs on park brake cable retainer, allowing cable to be removed from console bracket. From under carpet, grasp park brake cable housing and pull cable straight out of console bracket. 12. Raise vehicle on jackstands or centered on a frame contact type hoist. 13. Remove rear wheel and tire assembly. Rear Brake Drum Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Component Information > Service and Repair > Cable Removal > Page 4678 Rear Brake Rotor 14. On vehicles equipped with rear drum brakes, remove brake drum from rear hub/bearing assembly. On vehicles equipped with rear disc brakes, remove disc brake caliper from disc brake adapter, and then remove rotor from hub/ bearing assembly. Rear Hub/Bearing Dust Cap Removal 15. Remove dust cap from rear hub/ bearing assembly. Hub/Bearing Assembly Retaining Nut 16. Remove hub/bearing assembly retaining nut. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Component Information > Service and Repair > Cable Removal > Page 4679 Hub/Bearing Removal From Spindle (Drum Brakes Shown) 17. Remove the rear hub/bearing assembly from the rear spindle. Park Brake Cable Attachment To Actuating Lever Brake Adjustment Lever Actuating Spring 18. On vehicles equipped with rear drum brakes, remove park brake cable from park brake actuating lever. Then remove the actuating spring between brake shoe adjustment lever and brake shoe assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Component Information > Service and Repair > Cable Removal > Page 4680 Parking Brake Shoe Assemblies Parking Brake Actuator Lever 19. On vehicles equipped with rear disc brakes, remove brake shoe assemblies from rear disc brake adapter. Then remove parking brake actuating lever from the park brake cable. Park Brake Cable Removal From Brake Support Plate 20. On vehicles equipped with rear drum brakes, remove park brake cable from rear brake support plate. Park brake cable is removed from brake support plate using a 1/2 in. wrench as shown above to compress locking tabs on park brake cable retainer. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Component Information > Service and Repair > Cable Removal > Page 4681 Park Brake Cable Removal From Disc Brake Adapter 21. On vehicles equipped with rear disc brakes, remove park brake cable from rear disc brake adapter. Park brake cable is removed from disc brake adapter using a screwdriver as shown to compress locking tabs on park brake cable retainer. Park Brake Cable Routing Bracket 22. Remove park brake cable routing bracket from vehicle frame rail. Park Brake Cable Seal At Floor Pan 23. Remove park brake cable and sealing grommet from floor pan of vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Component Information > Service and Repair > Cable Removal > Page 4682 Parking Brake Cable: Service and Repair Cable Installation PROCEDURE 1. Install park brake cable into floor pan of vehicle making sure sealing grommet is installed in floor pan as far as possible to insure proper seal. 2. Install park brake cable into brake support plate or rear disc brake adapter. Be sure locking tabs on cable retainer are expanded to ensure park brake cable is securely held in support plate or adapter. Park Brake Cable Routing Bracket 3. Install park brake cable routing bracket on frame rail. Install and securely tighten routing bracket attaching bolt. Park Brake Cable Attachment To Actuating Lever Brake Adjustment Lever Actuating Spring 4. On vehicles equipped with rear drum brakes, install park brake cable on park brake cable actuating lever. Then install actuating spring between brake shoe assembly and brake adjustment lever. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Component Information > Service and Repair > Cable Removal > Page 4683 Parking Brake Shoe Assemblies Parking Brake Actuator Lever 5. On vehicles equipped with rear disc brakes, install park brake shoes actuator lever on park brake cable. Then install park brake shoe assemblies on disc brake adapter. 6. Install the hub/bearing assembly on the rear spindle. Then install A NEW rear hub/bearing assembly retaining nut. Torque hub/bearing assembly retaining nut to 217 Nm (160 ft. lbs.). 7. Install hub/bearing assembly dust cap, using a soft faced hammer. 8. On drum brake equipped vehicles, install rear brake drum on hub/bearing assembly. On vehicles equipped with rear disc brakes, install rotor on hub/ bearing assembly. Rear Caliper Guide Pin Bolts 9. On disc brake equipped vehicles install disc brake caliper on disc brake adapter. Install the 2 caliper guide pin bolts and torque to 22 Nm (192 in. lbs.). Refer to Disc Brake Caliper Service and Repair for installation procedure. 10. Install rear wheel and tire assembly on vehicle, tighten all wheel stud nuts in crisscross pattern to one-half specified torque. Then repeat pattern, fully tightening stud nuts to 109 - 150 Nm (80 - 110 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Component Information > Service and Repair > Cable Removal > Page 4684 11. Lower vehicle. Seal Grommet Installation In Floor Pan 12. Grasp park brake cable to floor pan seal grommet by hand, and pull it into floor pan to ensure seal grommet is fully seated into floor pan. Park Brake Cable Installed In Retaining Bracket 13. Route park brake cable under carpeting and up to park brake cable retaining bracket on floor pan. Then install park brake cable into retaining bracket. Be sure tabs on park brake cable retainer, have expanded out to hold park brake cable in retaining bracket. Park Brake Cables At Equalizer 14. Install rear park brake cables into equalizer on park brake lever cable. 15. Reposition rear carpeting. 16. Install both rear door sill plate scuff moldings, by snapping them onto rear door sills. 17. Install lower rear seat cushion. Be sure lower seat cushion is fully installed in retainers on floor pan of vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Component Information > Service and Repair > Cable Removal > Page 4685 Removing Lockout Pin From Park Brake Lever 18. Firmly grasp park brake lever locking pin (3/16 in. drill bit) and quickly remove it from the park brake lever mechanism. This will allow the park brake lever mechanism to correctly adjust the park brake cables. 19. Cycle park brake lever ounce to position park brake cables. Then return the park brake lever to its released position. Check the rear wheels of the vehicle, they should rotate freely without dragging. 20. Apply park brake to full engagement. 21. Install center console assembly. 22. Install the center console assembly attaching screws. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Other Service Bulletins for Diode: > 083696 > Nov > 96 > Customer Interest for Diode: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats Technical Service Bulletin # 07-04-98 Date: 980417 Cooling System - Fan ON Continuously/Overheats NO: 07-04-98 GROUP: Cooling DATE: Apr. 17, 1998 SUBJECT: Vehicle Overheats (Radiator Fan Inoperative) Or Radiator Fan Runs Continuously THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-97 DATED FEBRUARY 20, 1998 WHICH SHOULD BE NOTED IN THE 1997 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-98004). THE REVISION PROVIDES A NEW PART NUMBER FOR THE RADIATOR FAN RELAY. THE CHANGE IS HIGHLIGHTED WITH ASTERISKS. MODELS: 1997 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT AT TOLUCA ASSEMBLY PRIOR TO SEPTEMBER 11, 1997 (MDH 0911XX). TOLUCA ASSEMBLY IS DESIGNATED BY A "T" IN THE ELEVENTH POSITION OF THE VEHICLE IDENTIFICATION NUMBER. SYMPTOM/CONDITION: Vehicle overheats or radiator fan continues to run. DIAGNOSIS: Actuate the radiator fan relay using the DRB III. If the radiator fan does not come on or fan runs continuously, perform the Repair Procedure. PARTS REQUIRED: 1 05293157AA Jumper Wire With Diode, Radiator Fan **1 04707286 Relay, Radiator Fan** 2 06015756 Tie Strap POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-12-92 0.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves installing a radiator fan jumper wire assembly into the headlamp and dash wiring harness, and replacing the solid state relay. 1. Raise the hood and disconnect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Other Service Bulletins for Diode: > 083696 > Nov > 96 > Customer Interest for Diode: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 4695 2. Raise the vehicle on a suitable hoist. 3. Locate the left (driver's side) black fan motor connector. Retract the red latch on the two-way female connector, depress the thumb latch, and disconnect the connector from the fan (Figure 1). If the wiring to the fan motor is clipped into the fan support, gently pry it out of the hole so the fan is not damaged. 4. Pry out the two christmas tree type retainers located on the lower radiator enclosure reinforcement. 5. Install the jumper wire assembly (p/n 052931 57AA) between the radiator fan and the headlamp and dash harness: A. Attach the black two-way male connector with the clip into the outboard hole, so the connector faces outboard toward the left side of the vehicle. Attach the second clip into the inboard hole of the lower reinforcement that the original wiring came out of (Figure 2). B. Connect the original two-way black connector to the new mating connector installed in the previous step and slide the red latch into the locked position. 6. Connect the two-way female black connector on the new jumper assembly to the fan connector and slide the red latch into the locked position. If the original wiring to the fan was clipped into the fan support, snap the new clip on the jumper into the same hole. 7. Bundle the excess original fan wiring and tie strap to the main bundle of vehicle wiring in the front left corner in two places. NOTE: ENSURE THAT THE WIRING BUNDLE IS SECURE AND DOES NOT INTERFERE WITH ANY OTHER COMPONENTS. 8. The solid state fan relay is located on the left front rail. Retract the red latch on the black four-way connector and disconnect from the solid state fan relay. 9. Remove the two screws that secure the relay to the side of the left front rail and remove the relay. 10. Install the new solid state fan relay ** (p/n 04707286)** and locate the index pin on the relay into the locator hole in the rail. Secure with the two screws and torque to 5 N.m (45 in.lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > All Other Service Bulletins for Diode: > 083696 > Nov > 96 > Customer Interest for Diode: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 4696 11. Connect the four way connector and slide the red latch into the locked position. 12. Lower the vehicle and connect the negative battery cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations Power Distribution Center: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Page 4700 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions Power Distribution Center: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4703 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4704 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4705 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4706 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4707 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4708 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4709 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4710 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4711 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4712 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4713 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4714 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4715 Power Distribution Center: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4716 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4717 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4718 Power Distribution Center: Connector Views Power Distribution Center (Bottom) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4719 Power Distribution Center (Top) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4720 Power Distribution Center: Electrical Diagrams Power Distribution Power Distribution (Part 1 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4721 Power Distribution (Part 2 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4722 Power Distribution (Part 3 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4723 Power Distribution (Part 4 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4724 Power Distribution (Part 5 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4725 Power Distribution (Part 6 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4726 Power Distribution (Part 7 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4727 Power Distribution (Part 8 Of 8) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Ground Distribution Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4728 Ground Distribution (Part 1 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4729 Ground Distribution (Part 2 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4730 Ground Distribution (Part 3 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4731 Ground Distribution (Part 4 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4732 Ground Distribution (Part 5 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4733 Ground Distribution (Part 6 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4734 Ground Distribution (Part 7 Of 8) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4735 Ground Distribution (Part 8 Of 8) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations Fuse: Locations Fuse Locations Fuse Locations Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4743 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4744 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4745 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4746 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4747 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4748 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4749 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4750 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4751 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4752 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4753 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4754 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4755 Fuse Block: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4756 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4757 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4758 Fuse Block: Connector Views Fuse Block (Part 1 Of 2) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4759 Fuse Block (Part 2 Of 2) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4760 Fuse Block: Electrical Diagrams Fuse Block (Part 1 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4761 Fuse Block (Part 2 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4762 Fuse Block (Part 3 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4763 Fuse Block (Part 4 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4764 Fuse Block (Part 5 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4765 Fuse Block (Part 6 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4766 Fuse Block (Part 7 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4767 Fuse Block (Part 8 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4768 Fuse Block (Part 9 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4769 Fuse Block (Part 10 Of 11) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4770 Fuse Block (Part 11 Of 11) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Diagram Connector Pinout Revisions Multiple Junction Connector: Technical Service Bulletins Electrical - Wiring Diagram Connector Pinout Revisions NUMBER: 26-10-96C GROUP: Miscellaneous DATE: October, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Neon - Publication Number 81-270-7025 DESCRIPTION OF CHANGES Wiring diagram revisions to the connector pin-outs Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Diagram Connector Pinout Revisions > Page 4775 8W-43-3 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Diagram Connector Pinout Revisions > Page 4776 8W-80-5 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Wiring Diagram Connector Pinout Revisions > Page 4777 8W-80-7 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration Alignment: Customer Interest Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 4787 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 4788 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration Alignment: All Technical Service Bulletins Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 4794 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 4795 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment Alignment: All Technical Service Bulletins Alignment & Suspension - Specifications & Adjustment NO: 02-04-97 GROUP: Suspension DATE: May 16, 1997 SUBJECT: Front End Alignment Torque Specifications & Shock Adjustment Procedures On Competition Package MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH THE COMPETITION PACKAGE SALES CODE (ACR) SUSPENSION SALES CODE (SDK). DISCUSSION: The alignment on ACR equipped vehicles must be set to the preferred specifications provided in the 1997 Neon Service Manual (Publication Number 81-270-7025) page 2-7. After each final setting the nuts should then be torqued to 75 ft.lbs plus an additional 90 degree turn. It is important that the proper torque be used to maintain the proper alignment. If the alignment is outside of specifications, rapid and excessive tire wear will result. Starting in 1997, Neon competition package (ACR) vehicles come equipped with adjustable strut dampers on all four wheels. The struts are finely tuned to the ride and handling profile of the entire suspension system. If the customer wishes to change the dampening force for special conditions the dampening characteristics of the strut dampers are adjustable on the ACR equipped vehicles. The knob for adjusting the strut can be found in a packet located in the glove compartment. The adjustment procedures are as follows: 1. The top end of the adjusting rod has flats over which the adjusting knob will fit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment > Page 4800 2. Install the knob over the top end of the front or rear damper and lock it into position by turning counterclockwise slowly until the knob engages, (Illustration). 3. Turn the adjusting knob clockwise, if resistance is felt do not use force, as the damper is in an unadjusted position. Reverse the adjustment slightly and try again. When the damper is in the full clockwise position, this is the minimum (City Ride) position. 4. To adjust the dampening force, the adjusting knobs has to be turned in the direction of the arrow for increased dampening and the opposite direction for decreased dampening. NOTE: BOTH THE LEFT AND RIGHT STRUT DAMPERS MUST BE ADJUSTED IDENTICALLY. FAILURE TO DO SO COULD PRODUCE UNSTABLE HANDLING AND UNEVEN TIRE TREAD WEAR. 5. The following is a description of the various settings and the adjustment procedure. A. City Ride - To enjoy the most comfortable city ride, the struts should be left in the "minimum" position as they are set from the assembly plant. To set to minimum the knob should be turned completely clockwise. B. Cross Country - The cross country setting will give the car a firmer handling characteristic, but yet will still be very comfortable to drive. To set, turn the adjusting knob 1/2 turn counter clockwise from the "minimum" position. C. G.T./Aggressive Driving - This setting equates the car's handling to a cross-country grand turismo car, offering increased cornering ability, improved road feel and precise directional stability at higher speeds. To set turn the adjusting knob 1 turn counter clockwise from the "minimum" position. 6. Remove the adjusting knob before closing the hood or trunk. The vehicle should not be driven with the adjusting knob in place. NOTE: DURING INSPECTION/SERVICING A THIN FILM OF OIL AND DUST COLLECTION MAY BE NOTICED ON THE OUTSIDE OF THE STRUT TUBE. THIS IS A NORMAL CONDITION WHICH OCCURS DURING THE DAMPER INTERNAL SEAL "BREAK-IN" PERIOD AND DOES NOT AFFECT THE PERFORMANCE OF THE STRUT AND DOES NOT INDICATE THE NEED FOR STRUT REPLACEMENT. STRUT REPLACEMENT SHOULD ONLY OCCUR IF THE STRUT LEAKAGE IS SUFFICIENT TO COVER THE ENTIRE STRUT DAMPER TUBE AND HAS "DRIPPED" ONTO THE LOWER CONTROL ARM OR ONTO THE PAVEMENT DURING OVERNIGHT PARKING. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 26-12-96D > Dec > 96 > Steering/Suspension - Alignment Specifications Revisions Alignment: All Technical Service Bulletins Steering/Suspension - Alignment Specifications Revisions NUMBER: 26-12-96D GROUP: Miscellaneous DATE: December, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Neon - Publication Number 81-270-7025 DESCRIPTION OF CHANGES Revision the front end alignment specifications Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 26-12-96D > Dec > 96 > Steering/Suspension - Alignment Specifications Revisions > Page 4805 2-7 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment Alignment: All Technical Service Bulletins Alignment & Suspension - Specifications & Adjustment NO: 02-04-97 GROUP: Suspension DATE: May 16, 1997 SUBJECT: Front End Alignment Torque Specifications & Shock Adjustment Procedures On Competition Package MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH THE COMPETITION PACKAGE SALES CODE (ACR) SUSPENSION SALES CODE (SDK). DISCUSSION: The alignment on ACR equipped vehicles must be set to the preferred specifications provided in the 1997 Neon Service Manual (Publication Number 81-270-7025) page 2-7. After each final setting the nuts should then be torqued to 75 ft.lbs plus an additional 90 degree turn. It is important that the proper torque be used to maintain the proper alignment. If the alignment is outside of specifications, rapid and excessive tire wear will result. Starting in 1997, Neon competition package (ACR) vehicles come equipped with adjustable strut dampers on all four wheels. The struts are finely tuned to the ride and handling profile of the entire suspension system. If the customer wishes to change the dampening force for special conditions the dampening characteristics of the strut dampers are adjustable on the ACR equipped vehicles. The knob for adjusting the strut can be found in a packet located in the glove compartment. The adjustment procedures are as follows: 1. The top end of the adjusting rod has flats over which the adjusting knob will fit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment > Page 4811 2. Install the knob over the top end of the front or rear damper and lock it into position by turning counterclockwise slowly until the knob engages, (Illustration). 3. Turn the adjusting knob clockwise, if resistance is felt do not use force, as the damper is in an unadjusted position. Reverse the adjustment slightly and try again. When the damper is in the full clockwise position, this is the minimum (City Ride) position. 4. To adjust the dampening force, the adjusting knobs has to be turned in the direction of the arrow for increased dampening and the opposite direction for decreased dampening. NOTE: BOTH THE LEFT AND RIGHT STRUT DAMPERS MUST BE ADJUSTED IDENTICALLY. FAILURE TO DO SO COULD PRODUCE UNSTABLE HANDLING AND UNEVEN TIRE TREAD WEAR. 5. The following is a description of the various settings and the adjustment procedure. A. City Ride - To enjoy the most comfortable city ride, the struts should be left in the "minimum" position as they are set from the assembly plant. To set to minimum the knob should be turned completely clockwise. B. Cross Country - The cross country setting will give the car a firmer handling characteristic, but yet will still be very comfortable to drive. To set, turn the adjusting knob 1/2 turn counter clockwise from the "minimum" position. C. G.T./Aggressive Driving - This setting equates the car's handling to a cross-country grand turismo car, offering increased cornering ability, improved road feel and precise directional stability at higher speeds. To set turn the adjusting knob 1 turn counter clockwise from the "minimum" position. 6. Remove the adjusting knob before closing the hood or trunk. The vehicle should not be driven with the adjusting knob in place. NOTE: DURING INSPECTION/SERVICING A THIN FILM OF OIL AND DUST COLLECTION MAY BE NOTICED ON THE OUTSIDE OF THE STRUT TUBE. THIS IS A NORMAL CONDITION WHICH OCCURS DURING THE DAMPER INTERNAL SEAL "BREAK-IN" PERIOD AND DOES NOT AFFECT THE PERFORMANCE OF THE STRUT AND DOES NOT INDICATE THE NEED FOR STRUT REPLACEMENT. STRUT REPLACEMENT SHOULD ONLY OCCUR IF THE STRUT LEAKAGE IS SUFFICIENT TO COVER THE ENTIRE STRUT DAMPER TUBE AND HAS "DRIPPED" ONTO THE LOWER CONTROL ARM OR ONTO THE PAVEMENT DURING OVERNIGHT PARKING. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 26-12-96D > Dec > 96 > Steering/Suspension - Alignment Specifications Revisions Alignment: All Technical Service Bulletins Steering/Suspension - Alignment Specifications Revisions NUMBER: 26-12-96D GROUP: Miscellaneous DATE: December, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Neon - Publication Number 81-270-7025 DESCRIPTION OF CHANGES Revision the front end alignment specifications Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 26-12-96D > Dec > 96 > Steering/Suspension - Alignment Specifications Revisions > Page 4816 2-7 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4817 Alignment: By Symptom Technical Service Bulletin # 02-09-99 Date: 990702 Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4818 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4819 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Technical Service Bulletin # 02-09-99 Date: 990702 Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4820 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4821 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4822 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 4823 Alignment: Specifications The content of this article reflects changes called for in TSB 26-12-96. NOTE: All alignment specifications are taken at curb height. FRONT: Camber: Acceptable Range ................................................................................................................ ........................................................................ -0.4° to +0.4° Preferred Setting .................................. .............................................................................................................................................................. .......... 0.0° S/C ACR only [3] ............................................................................................................... .......................................................................... -2.4° to +0.4° Total Toe [1]: Acceptable Range ......................................................................................................... ........................................................................ 0.3° in to 0.1° out Preferred Setting ............................ .............................................................................................................................................................. ............ 0.1° in S/C ACR only [3] ......................................................................................................... ................................................................... 0.30° In to 0.70° Out Caster*: Acceptable Range ................................................................................................................. ....................................................................... +1.8° to +3.8° Preferred Setting .................................. .............................................................................................................................................................. ........ +2.8° * Side To Side Caster: Not To Exceed ................................................................................................ ................................................................................................. 1.0° or less REAR: Camber: Acceptable Range ................................................................................................................ .................................................................... -0.75° to +0.25° Preferred Setting .................................. .............................................................................................................................................................. ....... -0.25° S/C ACR only [3] ............................................................................................................... ...................................................................... -1.00° to +0.25° Total Toe [1] [2]: Acceptable Range .................................................................................................... .............................................................................. 0.3° in to 0.1°out Preferred Setting ....................... .............................................................................................................................................................. ................. 0.1° in S/C ACR only [3] .................................................................................................... ........................................................................ 0.30° In to 0.50° Out Thrust Angle ........................................................................................................................................ .................................................... -0.10° to +0.10° [1]: Total toe is the arithmetic sum of the left and right wheel toe settings. Positive is toe-in, negative is toe-out. Total toe must be equally split between each front wheel to ensure the steering wheel is centered after setting toe. Left and right toe must be equal to within 0.02 degrees. [2]: Toe-out when backed on to the alignment rack is toe in when driving. [3]: The alignment specifications shown, are only for vehicles which are equipped with the ACR (Competition Package) sales code. This specification is listed to show the adjustable range for the Camber and Toe on the front and rear suspension of a vehicle with the Competition Package. These alignment specifications are only to be used at the request of the vehicle owner and only when the vehicle is going to be used in a competition event. The alignment is to be set back to the preferred setting before the vehicle is returned to normal operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 4824 Alignment: Service Precautions CAUTION: Do not attempt to modify any suspension or steering components by heating or bending of the component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 4825 Alignment: Description and Operation GENERAL INFORMATION Proper vehicle wheel alignment is the proper adjustment of all interrelated front and rear suspension angles. These angles are what affects the handling and steering of the vehicle when it is in motion. The method of checking a vehicle's front and rear wheel alignment will vary depending on the type and manufacturer of the equipment being used. Instructions furnished by the manufacturer of the equipment being used should always be followed to ensure accuracy of the alignment, except alignment specifications recommended by Chrysler Corporation MUST ALWAYS be used. CAUTION: Do not attempt to modify any suspension or steering components by heating or bending of the component. ORDER OF ADJUSTMENTS Wheel alignment adjustments should be made in the following sequence, to ensure that an accurate alignment is performed. 1. Rear Wheel Toe Adjustment within specifications for both total toe and thrust angle. 2. Front Wheel Toe Adjustment within specifications for total toe. 3. Toe is measured in degrees or inches and is the distance that the front edges of the tires are closer (or farther apart) than the rear edges. 4. Thrust Angle is defined as the average of the Toe settings on each rear wheel. If this measurement is out of specification, re-adjust rear wheel Toe so that each wheel has 1/2 of the total Toe measurement. When re-adjusting, do not exceed the total Toe specification. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 4826 Alignment: Testing and Inspection CAUTION: If the front suspension crossmember shows any sign of impact damage, the steering column to steering gear coupling must be inspected. PRE-ALIGNMENT VEHICLE INSPECTION Before any attempt is made to change or correct the wheel alignment factors, the following inspection and necessary corrections must be made on those parts which influence the steering of the vehicle. 1. Be sure the fuel tank is full when the wheel alignment specifications are checked and or adjusted. A full tank of fuel weighs approximately 75 pounds, if the fuel tank is not full this reduction in weight will affect the curb height of the vehicle and the alignment specifications. 2. Alignment specifications of a vehicle can be the most accurately checked and set when the passenger compartment and trunk of the vehicle are vacant with the exception of the spare tire. People, luggage, and any other appreciable weight will adversely affect the checking and setting of the camber specification. 3. Check and if required, inflate all of the tires to the recommended air pressure. All tires must be of the same size and in good condition and have approximately the same tread wear. Note the type of tread wear on the tire, this will aid in diagnosing problems. 4. Check the front tire and wheel assemblies for radial runout. 5. Before beginning the alignment process, inspect all suspension component fasteners for looseness and/or loss of specified torque. 6. Inspect the lower front ball joints and all steering linkage for looseness and any signs of wear and or damage. 7. Inspect the tie rod ends for looseness and any signs of wear and or damage. 8. Inspect the rubber bushings on all suspension components for signs of wear or deterioration. If any bushings show signs of wear or deterioration they should be replaced prior to aligning the vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber Adjustment Bolt Package Installation Alignment: Service and Repair Camber Adjustment Bolt Package Installation 1. If front and or rear camber readings obtained are not within the required specification range, a Mopar (R) Service Kit is available to provide the required adjustment. The kit contains new bolts and nuts for the strut clevis bracket to steering knuckle attachment. The bolts contained in the service kit, are slightly undersize allowing for movement between the strut clevis bracket and steering knuckle. The movement allowed by the undersize bolts will provide approximately 2 degrees of camber adjustment per side of vehicle. To install new bolts in service kit follow the procedure below. CAUTION: The Mopar (R) Service Kit for allowing adjustment of front and rear camber are different for the front and rear of the vehicle. When using the service kits be sure that the front and rear strut attaching bolts are always used in the right location on the vehicle. 2. Raise front and or rear of vehicle until tires are not supporting the weight of the vehicle. CAUTION: The steering knuckle and rear knuckle to strut assembly attaching bolts are serrated and must not be turned during removal. Remove nuts while holding bolts stationary in the steering knuckles. 3. Remove original upper bolt attaching the front or rear strut clevis bracket to the steering knuckle or rear knuckle. 4. Loosen lower bolt attaching strut clevis bracket to steering knuckle or rear knuckle ONLY enough to allow knuckle to move in clevis bracket. 5. Install bolt from service kit into the upper strut clevis bracket to steering knuckle or rear knuckle mounting hole. CAUTION: Only the nuts supplied in the service kits MUST be used with the service kit replacement bolts. The original nuts will not properly secure the strut clevis bracket to steering knuckle or rear knuckle. 6. Install nut provided in service kit on the replacement bolt. 7. Tighten upper bolt and nut from service kit until snug, but still allowing movement between strut clevis bracket and knuckle. 8. Remove original lower bolt. Install bolt from service kit into the bottom hole of the strut clevis bracket. Install nut and snug. 9. Lower vehicle until full weight of vehicle is supported by the suspension and then jounce front and rear of vehicle an equal amount of times. 10. Adjust front and or rear camber to the preferred setting by pushing or pulling on the top of the front or rear tire. When camber is correctly set tighten upper and lower strut clevis bracket bolts. Again jounce front and rear of vehicle an equal amount of times and verify front and rear camber setting. 11. When vehicle is at correct camber setting torque both front strut clevis bracket to steering knuckle attaching bolts to 53 Nm (40 ft. lbs.) plus an additional 1/4 turn after required torque is met. Torque rear strut clevis bracket to rear knuckle attaching bolts to 95 Nm (70 ft. lbs.). 12. If Toe readings obtained are not within the required specification range, adjust Toe to meet the preferred specification setting. Toe is adjustable Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber Adjustment Bolt Package Installation > Page 4829 using the following Toe setting procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber Adjustment Bolt Package Installation > Page 4830 Alignment: Service and Repair Checking Wheel Alignment Angles GENERAL INFORMATION Front and rear Caster and Camber settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle's suspension components. This is called a Net Build vehicle and results in no required adjustment of Caster and Camber after vehicle is built or when servicing the suspension components. Thus Caster and Camber are not normally considered an adjustable specification when performing an alignment on this vehicle. Though Caster and Camber are not adjustable they must be checked to ensure they meet vehicle specifications. If front and or rear camber is found not to meet the vehicle alignment specifications, it can be adjusted using a Mopar (R) Service Kit developed to allow for camber adjustment. If a vehicle's front or rear camber is found to be outside the specifications, the vehicles suspension components should be inspected for any signs of damage on bending. This must be done before using the Mopar (R) Service Kit for setting camber to meet required specification. If a vehicles caster is not within manufacturers alignment specifications, check for damaged suspension components or body parts. This type of damage can cause component locations to move affecting vehicle alignment. No adjustment can be made for the Caster setting on this vehicle. CAUTION: Do not attempt to adjust the vehicles Caster or Camber by heating, bending or any other modification of the suspension components. PROCEDURE 1. Correctly position vehicle on alignment rack and install all required equipment on vehicle, per the alignment equipment manufacturers specifications. 2. Center the steering wheel and lock in place using a steering wheel clamp. NOTE: Prior to reading each alignment specification, jounce the front and rear of the vehicle an equal number of times. Induce jounce (rear first then front) by grasping center of bumper and jouncing each end of vehicle an equal number of times. Bumper should always be released when vehicle is at the bottom of the jounce cycle. 3. Correctly jounce vehicle and read front and rear alignment settings and compare to vehicle specifications for Camber, Caster and Toe. If front and rear camber readings are within required specifications proceed to step Step 3 in the Front And Rear Toe Setting procedure. If Camber readings are not within specifications refer to step Step 1 in the camber adjustment bolt package installation procedure, for the front and rear Camber adjustment procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber Adjustment Bolt Package Installation > Page 4831 Alignment: Service and Repair Front Alignment CAUTION: If the front suspension crossmember shows any sign of impact damage, the steering column to steering gear coupling must be inspected. Before any attempt is made to change or correct the wheel alignment factors, the following inspection and necessary corrections must be made on those parts which influence the steering of the vehicle. 1. Be sure the fuel tank is full when the wheel alignment specifications are checked and or adjusted. A full tank of fuel weighs approximately 75 pounds, if the fuel tank is not full this reduction in weight will affect the curb height of the vehicle and the alignment specifications. 2. Alignment specifications of a vehicle can be the most accurately checked and set when the passenger compartment and trunk of the vehicle are vacant with the exception of the spare tire. People, luggage, and any other appreciable weight will adversely affect the checking and setting of the camber specification. 3. Check and if required, inflate all of the tires to the recommended air pressure. All tires must be of the same size and in good condition and have approximately the same tread wear. Note the type of tread wear on the tire, this will aid in diagnosing problems. 4. Check the front tire and wheel assemblies for radial runout. 5. Before beginning the alignment process, inspect all suspension component fasteners for looseness and/or loss of specified torque. 6. Inspect the lower front ball joints and all steering linkage for looseness and any signs of wear and or damage. 7. Inspect the tie rod ends for looseness and any signs of wear and or damage. 8. Inspect the rubber bushings on all suspension components for signs of wear or deterioration. If any bushings show signs of wear or deterioration they should be replaced prior to aligning the vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber Adjustment Bolt Package Installation > Page 4832 Alignment: Service and Repair Front and Rear Toe Setting Procedure 1. Prepare vehicle as described in the Pre-Alignment Vehicle Inspection procedure. 2. Center steering wheel and lock in place using a steering wheel clamp. 3. When performing the Toe setting procedure, set rear wheel Toe to preferred specification first, then set front wheel Toe to the preferred specification. 4. Loosen nuts on attaching bolts, for the left and right rear lateral links to rear crossmember. 5. Rotate lateral link adjustment cams until the preferred rear Toe specification is obtained. 6. While holding Toe adjustment cams from turning, tighten left and right lateral links to rear crossmember attaching bolt nuts. This will securely hold adjustment cams in position. Then while holding lateral link attaching bolt and adjustment cam from turning, torque nut of lateral link attaching bolt to 95 Nm (70 ft. lbs.). CAUTION: Do not twist front inner tie rod to steering gear rubber boots during front wheel Toe adjustment. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber Adjustment Bolt Package Installation > Page 4833 7. Loosen inner to outer tie rod end jam nuts. Grasp inner tie rods at serrations and rotate tie rods to set the front wheel Toe to the preferred specification. 8. Tighten tie rod locknuts to 54 Nm (40 ft. lbs.) torque. 9. Adjust steering gear to tie rod boots at tie rod. 10. Remove steering wheel clamp. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber Adjustment Bolt Package Installation > Page 4834 Alignment: Service and Repair Order of Adjustments Wheel alignment adjustments should be made in the following sequence, to ensure that an accurate alignment is performed. 1. Rear Wheel Toe Adjustment within specifications for both total toe and thrust angle. 2. Front Wheel Toe Adjustment within specifications for total toe. 3. Toe is measured in degrees or inches and is the distance that the front edges of the tires are closer (or farther apart) than the rear edges. 4. Thrust Angle is defined as the average of the Toe settings on each rear wheel. If this measurement is out of specification, re-adjust rear wheel Toe so that each wheel has 1/2 of the total Toe measurement. When re-adjusting, do not exceed the total Toe specification. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 4841 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 4842 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 4843 Power Steering Pressure Switch: Description and Operation Fig. 15 Power Steering Pressure Switch PURPOSE On vehicles equipped with power steering, a power steering pressure switch is used to improve the vehicle's idle quality. The pressure switch improves vehicle idle quality, by controlling engine idle speed when required. The switch (Fig. 15) provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. OPERATION The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed is increased. This increase in engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. When power steering pump pressure exceeds 2,758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. The power steering pressure switch is mounted directly to the power steering gear on vehicles requiring its usage. CIRCUIT OPERATION The power steering pressure switch opens and closes circuit K10 between the Powertrain Control Module (PCM) and ground. Circuit K10 connects to cavity 45 of the PCM connector. Circuit Z12 provides ground for the power steering pressure switch. The grounding point for circuit Z12 is the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 4844 Power Steering Pressure Switch: Service and Repair CAUTION: When removing and installing the power steering pressure switch, the use of a 7/8 inch deep well socket is required. The deep well socket will prevent damage to the plastic, electrical connector area, of the power steering pressure switch. REMOVE 1. Disconnect negative battery cable from the negative post of the battery. Be sure cable is isolated from negative post on battery. 2. Raise vehicle. 3. Locate power steering pressure switch on back side of power steering gear. 4. Remove vehicle wiring harness connector, from power steering pressure switch. 5. Remove power steering pressure switch, from power steering gear. CAUTION: When tightening the power steering pressure switch after installation in steering gear, do not exceed the torque specification shown in step 1 below. Over-tightening may result in stripping the threads out of the pressure switch port on the steering gear. INSTALL 1. Install power steering pressure switch into power steering gear by hand until fully seated. Then torque power steering pressure switch to 8 Nm (70 inch lbs.). 2. Install vehicle wiring harness connector onto power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with locking tab on power steering pressure switch. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar (R), Power Steering Fluid, or equivalent. 3. Fill power steering reservoir to correct fluid level. 4. Connect negative cable back on negative post of battery. 5. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Customer Interest for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension Popping/Creaking Noises Front Steering Knuckle: Customer Interest Front Suspension - Popping/Creaking Noises NO: 02-02-97 Rev. A GROUP: Front Suspension EFFECTIVE DATE: Dec. 15, 1997 SUBJECT: Popping/Creaking Noise in Front Suspension THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-02-97 DATED FEBRUARY 28, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL FRONT SUSPENSION NOISE DIAGNOSTICS/REPAIRS HAVE BEEN ADDED. THE ADDITIONS ARE HIGHLIGHTED WITH ASTERISKS. MODELS: 1995 - 1998 (PL) Neon SYMPTOM/CONDITION: **A popping noise from the front suspension may be experienced while: ^ Going in reverse or forward with the steering wheel turned completely in one direction (parking lot maneuvers). ^ Shifting from drive to reverse, reverse to drive, etc. ^ Pulling in/out of driveway. ^ Large dips/bumps in the road such as speed bumps. ** DIAGNOSIS: If the customer describes the front suspension noise in conditions such as those described above, perform the Repair Procedure. PARTS REQUIRED: NOTE: THE 1995 NEONS BUILT IN 1994 USED 13" KNUCKLE ASSEMBLIES WITH 13" OR 14" WHEELS. LATER BUILT VEHICLES HAVE 13" OR 14" KNUCKLE ASSEMBLIES TO MATCH ORIGINAL WHEEL SIZE. TO DETERMINE THE PROPER KNUCKLE SIZE, COUNT THE STUDS ON THE HUB THEN REFER TO THE PARTS LIST PROVIDED IN THIS BULLETIN. CAUTION: DO NOT USE THE WHEEL SIZE TO DETERMINE PROPER KNUCKLE PART NUMBERS. REPAIR PROCEDURE: **This bulletin involves inspecting/replacing as needed both front wheel bearings and steering knuckles, front upper strut mounts, engine mounts, and lubing the driveshafts.** Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Customer Interest for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension Popping/Creaking Noises > Page 4854 **NOTE: USE TABLE TO DETERMINE WHICH STEPS TO PERFORM BASED ON VEHICLE BUILD DATE AND IF TECHNICAL SERVICE BULLETIN 02-02-97, DATED FEBRUARY 28, 1997 HAS BEEN PERFORMED.** NOTE: ALL FRONT KNUCKLE/BEARING/HUB REPAIR PROCEDURES FOR STEPS 1 THROUGH 5, CAN BE FOUND IN THE 1998 NEON SERVICE MANUAL (PUBLICATION NUMBER 81-270-8025) GROUP 2 (SUSPENSION). 1. Remove both left and right front knuckle/bearing/hub assemblies. 2. Press the hub out of the old knuckle/bearing/hub assemblies. 3. Press the old hubs into the new knuckle/bearing assemblies. **4. Before the knuckle/bearing/hub assemblies are installed on the vehicle, put a small amount of grease (Wheel Bearing Lube - p/n 04318064) on the entire face of the driveshaft that makes contact with the hub bearing assembly (Figure 1).** 5. Install both left and right front knuckle/bearing/hub assemblies. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Customer Interest for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension Popping/Creaking Noises > Page 4855 **6. Replace the upper strut mount by following the procedures in the 1998 Neon Service Manual (Publication No. 81-270-8025), Removal/Installation, pages 2-16 to 2-17, and Assembly/Disassembly procedures 1 thru 5 on pages 2-30 to 2-31 (Figure 2). The torque for the new upper strut mount nuts is 61 Nm (45 ft.lbs).** **7. Remove and replace the right engine mount as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) (SOHC - pg 9-18)(DOHC - pg 9-64). After replacing the right engine mount, squirt enough grease (Silicone Spray - p/n 04318070) between the mount snubber and the engine bracket to fill the gap (Figure 3).** NOTE: IF THE SILICONE SPRAY (P/N 04318070) IS NOT AVAILABLE, ANOTHER SILICONE SPRAY MAY BE USED. HOWEVER THE SUBSTITUTE SILICONE SPRAY MUST NOT BE PETROLEUM BASED. **8. Inspect and tighten remaining suspension components to specification; repair or replace as needed.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-05-30-93 Knuckles and Mounts - Replace - All 2.9 Hrs. 02-05-39-91 Upper Strut Mounts and Engine Mount - Replace 1.3 Hrs. 09-40-21-91 Engine Mount Replace 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension - Popping/Creaking Noises Front Steering Knuckle: All Technical Service Bulletins Front Suspension - Popping/Creaking Noises NO: 02-02-97 Rev. A GROUP: Front Suspension EFFECTIVE DATE: Dec. 15, 1997 SUBJECT: Popping/Creaking Noise in Front Suspension THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-02-97 DATED FEBRUARY 28, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL FRONT SUSPENSION NOISE DIAGNOSTICS/REPAIRS HAVE BEEN ADDED. THE ADDITIONS ARE HIGHLIGHTED WITH ASTERISKS. MODELS: 1995 - 1998 (PL) Neon SYMPTOM/CONDITION: **A popping noise from the front suspension may be experienced while: ^ Going in reverse or forward with the steering wheel turned completely in one direction (parking lot maneuvers). ^ Shifting from drive to reverse, reverse to drive, etc. ^ Pulling in/out of driveway. ^ Large dips/bumps in the road such as speed bumps. ** DIAGNOSIS: If the customer describes the front suspension noise in conditions such as those described above, perform the Repair Procedure. PARTS REQUIRED: NOTE: THE 1995 NEONS BUILT IN 1994 USED 13" KNUCKLE ASSEMBLIES WITH 13" OR 14" WHEELS. LATER BUILT VEHICLES HAVE 13" OR 14" KNUCKLE ASSEMBLIES TO MATCH ORIGINAL WHEEL SIZE. TO DETERMINE THE PROPER KNUCKLE SIZE, COUNT THE STUDS ON THE HUB THEN REFER TO THE PARTS LIST PROVIDED IN THIS BULLETIN. CAUTION: DO NOT USE THE WHEEL SIZE TO DETERMINE PROPER KNUCKLE PART NUMBERS. REPAIR PROCEDURE: **This bulletin involves inspecting/replacing as needed both front wheel bearings and steering knuckles, front upper strut mounts, engine mounts, and lubing the driveshafts.** Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension - Popping/Creaking Noises > Page 4861 **NOTE: USE TABLE TO DETERMINE WHICH STEPS TO PERFORM BASED ON VEHICLE BUILD DATE AND IF TECHNICAL SERVICE BULLETIN 02-02-97, DATED FEBRUARY 28, 1997 HAS BEEN PERFORMED.** NOTE: ALL FRONT KNUCKLE/BEARING/HUB REPAIR PROCEDURES FOR STEPS 1 THROUGH 5, CAN BE FOUND IN THE 1998 NEON SERVICE MANUAL (PUBLICATION NUMBER 81-270-8025) GROUP 2 (SUSPENSION). 1. Remove both left and right front knuckle/bearing/hub assemblies. 2. Press the hub out of the old knuckle/bearing/hub assemblies. 3. Press the old hubs into the new knuckle/bearing assemblies. **4. Before the knuckle/bearing/hub assemblies are installed on the vehicle, put a small amount of grease (Wheel Bearing Lube - p/n 04318064) on the entire face of the driveshaft that makes contact with the hub bearing assembly (Figure 1).** 5. Install both left and right front knuckle/bearing/hub assemblies. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension - Popping/Creaking Noises > Page 4862 **6. Replace the upper strut mount by following the procedures in the 1998 Neon Service Manual (Publication No. 81-270-8025), Removal/Installation, pages 2-16 to 2-17, and Assembly/Disassembly procedures 1 thru 5 on pages 2-30 to 2-31 (Figure 2). The torque for the new upper strut mount nuts is 61 Nm (45 ft.lbs).** **7. Remove and replace the right engine mount as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) (SOHC - pg 9-18)(DOHC - pg 9-64). After replacing the right engine mount, squirt enough grease (Silicone Spray - p/n 04318070) between the mount snubber and the engine bracket to fill the gap (Figure 3).** NOTE: IF THE SILICONE SPRAY (P/N 04318070) IS NOT AVAILABLE, ANOTHER SILICONE SPRAY MAY BE USED. HOWEVER THE SUBSTITUTE SILICONE SPRAY MUST NOT BE PETROLEUM BASED. **8. Inspect and tighten remaining suspension components to specification; repair or replace as needed.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-05-30-93 Knuckles and Mounts - Replace - All 2.9 Hrs. 02-05-39-91 Upper Strut Mounts and Engine Mount - Replace 1.3 Hrs. 09-40-21-91 Engine Mount Replace 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 4863 Front Steering Knuckle: Description and Operation The steering knuckle is a single casting with legs machined for attachment to the front strut assembly and lower control arm ball joint. The steering knuckle also has machined abutments on the casting to support and align the front brake caliper assembly. The knuckle also holds the front drive shaft outer C/V joint hub and bearing assembly. The hub is positioned through the bearing and knuckle, with the constant velocity stub shaft splined through the hub. The outer C/V joint is retained to the hub/ bearing using a hub nut. The hub nut is held on the stub shaft using a nut retainer and cotter pin. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 4864 Front Steering Knuckle: Testing and Inspection The front suspension steering knuckle is not a repairable component of the front suspension. IT MUST BE REPLACED IF FOUND TO BE DAMAGED IN ANY WAY. If it is determined that the steering knuckle is bent when servicing the vehicle, no attempt is to be made to straighten the steering knuckle. NOTE: On this vehicle the steering knuckle must be removed from the vehicle when servicing the front hub bearing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal Front Steering Knuckle: Service and Repair Removal 1. Remove cotter pin, nut lock, and spring washer. CAUTION: Wheel bearing damage will result if after loosening hub nut, vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires. 2. Loosen hub nut while vehicle is on the floor with the brakes applied. The hub and driveshaft are splined together through the knuckle (bearing) and retained by the hub nut. 3. Raise vehicle on jack stands or centered on a frame contact type hoist. 4. Remove wheel lug nuts, and front tire and wheel assembly from the hub. 5. Remove front disc brake caliper to steering knuckle attaching bolts. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 4867 6. Remove disc brake caliper assembly from steering knuckle. Caliper is removed by first lifting bottom of caliper away from steering knuckle, and then removing top of caliper out from under steering knuckle. 7. Support brake disc brake caliper assembly using a wire hook and not by hydraulic hose. 8. Remove the braking disc from the front hub/ bearing assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 4868 9. Remove the nut attaching outer tie rod end to the steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with wrench. 10. Remove the tie rod end stud from steering knuckle arm, using Remover, Special Tool MB-990635, or equivalent. 11. Remove nut and bolt, clamping ball joint stud, from steering knuckle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 4869 12. Separate ball joint stud from steering knuckle by prying down on lower control arm. NOTE: Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get cut. - Care must be taken not to separate the inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint, driveshaft must be supported. 13. Pull steering knuckle assembly out and away from outer C/V joint of the driveshaft assembly. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during removal. Remove nuts while holding bolts stationary in the steering knuckles. 14. Remove the 2 steering knuckle to strut damper clevis bracket attaching bolts. 15. The cartridge type front wheel bearing used on this vehicle is not transferable to the replacement steering knuckle. If the replacement steering knuckle does not come with a hub and bearing assembly, a new bearing must be installed in the steering knuckle. Installation of the new wheel bearing must be done before installing steering knuckle on vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 4870 Front Steering Knuckle: Service and Repair Installation 1. Install a new cartridge hub and bearing assembly into the steering knuckle. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in the steering knuckles. 2. Install steering knuckle back in clevis bracket of strut damper assembly. Install the strut damper to steering knuckle attaching bolts. Note: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned in steering knuckle during installation. Torque attaching nuts to 54 Nm (40 ft. lbs.) plus an additional 1/4 turn after specified torque is met. 3. Slide drive shaft back into front hub and bearing assembly. Then install steering knuckle onto the ball joint stud. 4. Install a NEW steering knuckle to ball joint stud, clamp bolt and nut. Torque the clamp bolt to 100 Nm (75 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 4871 5. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket, torque tie rod end attaching nut to 55 Nm (40 ft. lbs.). 6. Install braking disc back on hub and bearing assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 4872 7. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding top of caliper under top abutment on steering knuckle. Then installing bottom of caliper against bottom abutment of steering knuckle. 8. Install caliper assembly to steering knuckle attaching bolts. Torque caliper assembly attaching bolts to 31 Nm (23 ft. lbs.). 9. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install hub nut onto threads of stub axle and tighten nut. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 4873 10. With vehicle brakes applied to keep braking disc from turning, tighten hub nut to a torque of 183 Nm (135 ft. lbs.). 11. Install front wheel and tire assembly. Install front wheel lug nuts and torque to 135 Nm (100 ft. lbs.). 12. Lower vehicle. 13. Install the spring washer, hub nut lock, and new cotter pin. Wrap cotter pin prongs tightly around the hub nut lock. 14. Set front Toe on vehicle to required specification. Refer to Alignment. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Fluid: Customer Interest Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 4883 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4889 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4890 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4891 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Fluid: All Technical Service Bulletins Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 4896 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4902 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4903 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4904 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 4905 Power Steering Fluid: Specifications WARNING: Fluid level should be checked with engine off to prevent injury from moving parts. Do not use automatic transmission fluid in the power steering system. Do not overfill the power steering system. Wipe reservoir filler cap free of dirt. Then check fluid level. The dipstick should indicate COLD when fluid is at normal ambient temperature, approximately 21°C - 27°C (70°F - 80°F). In all pumps add fluid as necessary, use only Mopar (R) Power Steering Fluid, or equivalent. DO NOT USE ANY TYPE OF AUTOMATIC TRANSMISSION FLUID. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 4906 Power Steering Fluid: Service and Repair WARNING: Fluid level should be checked with engine off to prevent injury from moving parts. Do not use automatic transmission fluid in the power steering system. Do not overfill the power steering system. Wipe reservoir filler cap free of dirt. Then check fluid level. The dipstick should indicate COLD when fluid is at normal ambient temperature, approximately 21°C - 27°C (70°F - 80°F). In all pumps add fluid as necessary, use only Mopar (R) Power Steering Fluid, or equivalent. DO NOT USE ANY TYPE OF AUTOMATIC TRANSMISSION FLUID. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair Power Steering Fluid Reservoir: Service and Repair REMOVE 1. Raise vehicle on jack stands or on a frame contact type hoist. 2. Remove hose clamp, attaching return hose to steel tube at power steering gear. Let power steering fluid drain from return hose and power steering fluid reservoir, until reservoir is empty. 3. Lower vehicle. 4. Remove the coolant overflow hose from the Coolant Recovery System (CRS) tank. NOTE: Removal of the CRS tank improves access to the power steering fluid reservoir attaching bolts. 5. Remove the nut and screw attaching the CRS tank to the dash panel. Remove the CRS tank from the dash panel and lower it down on top of the steering gear toward the center of the vehicle CAUTION: Care must be used when removing and installing power steering fluid hoses on the power steering fluid reservoir. If excessive force is used when trying to remove or install hoses on nipples of power steering fluid reservoir, nipples can be broken off the reservoir. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Page 4910 6. Remove the power steering fluid return and supply hose from the power steering fluid reservoir. 7. If vehicle is equipped with the single overhead cam engine, remove the 3 bolts attaching the power steering fluid reservoir to the cylinder head. 8. If vehicle is equipped with the dual overhead cam engine, remove the 2 nuts attaching the power steering fluid reservoir to the cylinder head. 9. Remove power steering fluid reservoir from vehicle. INSTALL 1. Install power steering fluid reservoir on cylinder head. Install and securely tighten the power steering fluid reservoir to cylinder head attaching bolts. 2. Install the power steering fluid return and supply hose, on the power steering fluid reservoir fittings. Be sure both hose clamps are installed on hose past upset bead on power steering reservoir fittings. 3. Install engine coolant recovery system tank on dash panel of vehicle. Install and securely tighten attaching bolts. 4. Install the coolant overflow hose from the CRS tank. 5. Raise vehicle. 6. Install power steering return hose, on the steel tube at the power steering gear. Be sure hose clamp is installed on hose past upset bead on power steering gear steel tube. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Page 4911 7. Fill power steering pump fluid reservoir to the proper level. 8. Start the engine and let run for a few seconds. Then turn the engine off. 9. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 10. Raise front wheels of vehicle off the ground. 11. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Then turn the engine off. 12. Add power steering fluid if necessary. 13. Lower the vehicle and turn the steering wheel slowly from lock to lock. 14. Stop the engine. Check the fluid level and refill as required. 15. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Pressure and Return Line Tube Nuts ................................................................................................................................................... 31 Nm (275 inch lbs.) Pressure Hose Banjo Bolt ..................................................................................... .................................................................................... 34 Nm (25 ft. lbs.) Routing Bracket ................ .............................................................................................................................................................. .......... 23 Nm (17 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump Power Steering Line/Hose: Service and Repair Supply Hose From Reservoir to Pump WARNING: Power steering oil, engine parts and exhaust system may be extremely hot if engine has been running. Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch hot exhaust manifold or catalyst. CAUTION: Care must be used when removing the power steering fluid supply hose from power steering fluid reservoir. If excessive force is used when trying to remove hose from nipple on power steering fluid reservoir, nipple can break off of the reservoir. REMOVE 1. Remove hose clamp, attaching power steering fluid supply hose to power steering fluid reservoir. Then remove power steering fluid supply hose from power steering fluid reservoir. 2. Remove hose clamp, attaching power steering fluid supply hose to the power steering pump. Then remove power steering fluid supply hose from power steering pump fitting. 3. Remove power steering fluid supply hose from engine. INSTALL 1. Install power steering fluid supply hose back on engine making sure it is correctly routed. CAUTION: Care must be used when installing power steering fluid supply hose on power steering fluid reservoir. If excessive force is used when trying to install hose on nipple of power steering fluid reservoir, nipple can be broken off the reservoir. 2. Install power steering fluid supply hose on power steering fluid reservoir fitting. Install hose clamp on power steering fluid supply hose at power steering fluid reservoir. Be sure hose clamp is installed on return hose past upset bead on power steering fluid reservoir. 3. Install power steering fluid supply hose on power steering pump fitting. Install hose clamp on power steering fluid supply hose at power steering pump fitting. Be sure hose clamp is installed on power steering fluid supply hose past upset bead on power steering pump fitting. 4. Start the engine and let run for a few seconds. Then turn the engine off. 5. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 6. Raise front wheels of vehicle off the ground. 7. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Then turn the engine off. 8. Add power steering fluid if necessary. 9. Lower the vehicle and turn the steering wheel slowly from lock to lock. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 4917 10. Stop the engine. Check the fluid level and refill as required. 11. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. 12. After hose is installed, check for leaks at all hose connections. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 4918 Power Steering Line/Hose: Service and Repair Power Steering Fluid Pressure Hose Removal CAUTION: Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent entry of foreign material into the components. WARNING: Power steering oil, engine parts and exhaust system may be extremely hot if engine has been running. Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch hot exhaust manifold or catalyst. 1. Raise vehicle. 2. Remove bolt attaching power steering hose routing bracket to front suspension crossmember. 3. Disconnect power steering pressure hose at power steering gear. Drain power steering fluid from power steering pump and hose through open end of hose. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 4919 4. Remove power steering pressure hose from routing clip on generator shield. 5. Lower vehicle. 6. Remove bolt, attaching power steering pressure hose routing clip, to generator shield. 7. Loosen and remove Banjo bolt, and power steering pressure hose from pressure fitting on power steering pump. 8. Power steering fluid pressure hose is removed from the vehicle from the top of the engine compartment. 9. Discard all used O-rings located at ends of power steering pressure hose and Banjo bolt. Installation 1. Install power steering pressure hose in vehicle from top of engine compartment. 2. Using a lint free towel, wipe clean all open power steering hose ends, and the power steering pump and steering gear ports. 3. Install new O-ring on end of power steering pressure hose banjo fitting. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 4920 4. Install a new O-ring on power steering pressure hose banjo fitting bolt. 5. Lubricate both O-rings using fresh clean power steering fluid. 6. Install banjo bolt into the power steering pressure hose banjo fitting. 7. Attach power steering pressure hose to outlet fitting on power steering pump. Do not tighten or torque pressure fitting Banjo bolt at this time. 8. Correctly route power steering pressure hose avoiding tight bends or kinking of the hose. Install power steering pressure hose to generator shield routing clip attaching screw but do not tighten at this time. 9. Raise vehicle. CAUTION: Hoses must remain away from exhaust system, vehicle components and unfriendly surfaces causing possible damage to power steering hoses. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 4921 10. Route power steering pressure hose to pressure port on power steering gear. Install power steering pressure hose, on steering gear and loosely install tube nut into steering gear. Tighten and torque tube nut after routing bracket is installed, correctly positioning hoses in vehicle. 11. Install the power steering pressure and return hose routing clip on hoses. Install bolt attaching routing clip to front suspension crossmember. Torque routing clip to front suspension crossmember attaching bolt to 23 Nm (17 ft. lbs.). 12. Torque power steering pressure hose to steering gear tube nut to 34 Nm (25 ft. lbs.). 13. Install power steering pressure hose in routing clip on generator shield. 14. Lower Vehicle. 15. Position locating pin on power steering pressure hose banjo fitting so it is against power steering pump mounting bracket. While holding locating pin against power steering pump bracket, torque pump end Banjo bolt to 34 Nm (25 ft. lbs.). 16. Securely tighten bolt attaching power steering pressure hose bracket to generator shield. 17. Start the engine and let run for a few seconds. Then turn the engine off. 18. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 19. Raise front wheels of vehicle off the ground. 20. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Then turn the engine off. 21. Add power steering fluid if necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 4922 22. Lower the vehicle and turn the steering wheel slowly from lock to lock. 23. Stop the engine. Check the fluid level and refill as required. 24. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. 25. After hose is installed, check for leaks at all hose connections. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 4923 Power Steering Line/Hose: Service and Repair Power Steering Fluid Return Hose CAUTION: Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent entry of foreign material into the components. WARNING: Power steering oil, engine parts and exhaust system may be extremely hot if engine has been running. Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch hot exhaust manifold or catalyst. REMOVE 1. Raise vehicle. 2. Remove hose clamp, attaching return hose to steel tube at power steering gear. Let power steering fluid, drain from return hose and power steering fluid reservoir, until reservoir is empty. 3. Remove power steering return hose from routing clip on generator shield. 4. Lower vehicle. 5. Remove tube clip at generator shield attaching power steering fluid return hose to power steering fluid pressure hose. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 4924 CAUTION: Care must be used when removing power steering fluid return hose from power steering fluid reservoir. If excessive force is used when trying to remove hose from nipple on power steering fluid reservoir, nipple can break off of the reservoir. 6. Remove hose clamp, attaching power steering return hose to power steering fluid reservoir. Then remove power steering return hose from power steering fluid reservoir 7. Remove the power steering return hose from the vehicle. The power steering return hose is removed from the top of the engine compartment. INSTALL 1. Install power steering return hose on vehicle. Power steering return hose is installed from the top of the vehicles engine compartment. CAUTION: Care must be used when installing power steering fluid return hose on power steering fluid reservoir. If excessive force is used when trying to install hose on nipple of power steering fluid reservoir, nipple can be broken off the reservoir. 2. Install power steering return hose on power steering fluid reservoir fitting. Install hose clamp on power steering return hose at power steering fluid reservoir. Be sure hose clamp is installed on return hose past upset bead on power steering fluid reservoir. 3. Raise vehicle. 4. Clip power steering return hose and pressure hose together. 5. Install power steering return hose on steel tube at power steering gear. Install hose clamp on power steering return hose at power steering gear. Be sure hose clamp is installed on return hose past upset bead on steel tube at power gear. 6. Install power steering return hose on routing clip at generator shield. 7. Lower vehicle. 8. Start the engine and let run for a few seconds. Then turn the engine off. 9. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 10. Raise front wheels of vehicle off the ground. 11. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Then turn the engine off. 12. Add power steering fluid if necessary. 13. Lower the vehicle and turn the steering wheel slowly from lock to lock. 14. Stop the engine. Check the fluid level and refill as required. 15. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. 16. After hose is installed, check for leaks at all hose connections. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Pump: Customer Interest Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 4933 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist Power Steering Pump: Customer Interest Drive Belt - Momentary Loss of Power Steering Assist NO: 07-04-97 GROUP: Accessory Belt DATE: Jun. 6, 1997 SUBJECT: Momentary Loss Of Power Steering Assist When Driving Through Heavy Rain - Deep Puddles MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Momentary loss of power steering assist when driving through heavy rain and/or deep puddles. Loss of power steering is caused by water intrusion into the accessory drive belt area. DIAGNOSIS: Inspect the belt for glazing and/or cracks, if either is found replace the belt following the repair procedure found in the 1997 Neon Service Manual (Publication No. 81-270-7025) Page 7-21. Determine the road conditions the driver of the vehicle was encountering at the time the loss of power assist was experienced. If the driver indicates the loss of power steering assist was during times of heavy rain or deep puddles, perform the Repair Procedure. PARTS REQUIRED: AR(1) 04612247 Belt, Accessory Drive - Power steering and A/C Compressor REPAIR PROCEDURE: This bulletin involves correcting the tension on the power steering accessory drive belt. 1. Loosen the power steering pump locking bolts A and B and pivot bolt C (Illustration) to allow adjustment of belt tension. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist > Page 4938 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square hole "D" on the power steering pivot bracket. Adjust the tension as follows: Belt tension with no belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 100 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). Belt tension with belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 135 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). C. Start the engine and allow the vehicle to idle for 15 minutes to allow the belt to seat. D. Repeat the belt tensioning procedure, set belt tension to 135 lb. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-11-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Pump: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4944 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4945 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4946 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Pump: All Technical Service Bulletins Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 4951 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist Power Steering Pump: All Technical Service Bulletins Drive Belt - Momentary Loss of Power Steering Assist NO: 07-04-97 GROUP: Accessory Belt DATE: Jun. 6, 1997 SUBJECT: Momentary Loss Of Power Steering Assist When Driving Through Heavy Rain - Deep Puddles MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Momentary loss of power steering assist when driving through heavy rain and/or deep puddles. Loss of power steering is caused by water intrusion into the accessory drive belt area. DIAGNOSIS: Inspect the belt for glazing and/or cracks, if either is found replace the belt following the repair procedure found in the 1997 Neon Service Manual (Publication No. 81-270-7025) Page 7-21. Determine the road conditions the driver of the vehicle was encountering at the time the loss of power assist was experienced. If the driver indicates the loss of power steering assist was during times of heavy rain or deep puddles, perform the Repair Procedure. PARTS REQUIRED: AR(1) 04612247 Belt, Accessory Drive - Power steering and A/C Compressor REPAIR PROCEDURE: This bulletin involves correcting the tension on the power steering accessory drive belt. 1. Loosen the power steering pump locking bolts A and B and pivot bolt C (Illustration) to allow adjustment of belt tension. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist > Page 4956 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square hole "D" on the power steering pivot bracket. Adjust the tension as follows: Belt tension with no belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 100 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). Belt tension with belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 135 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). C. Start the engine and allow the vehicle to idle for 15 minutes to allow the belt to seat. D. Repeat the belt tensioning procedure, set belt tension to 135 lb. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-11-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Pump: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4962 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4963 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4964 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Bracket To Front Crossmember Attaching Bolts ...................................................................................................................................... 23 Nm (17 ft. lbs.) Discharge Fitting .......................................................................................................................... ............................................................ 75 Nm (55 ft. lbs.) To Bracket Mounting Bolts ........................ .............................................................................................................................................. 54 Nm (40 ft. lbs.) Bracket To Engine Mounting ............................................................................................. ...................................................................... 54 Nm (40 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 4967 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Minimum Pressure At 1500 RPM ............................................................................................................................. 4.9 - 5.3 liters/minute (1.3 - 1.9 GPM) Control Valve Pressure Relief ......................................................................................................................................... 8240 - 8920 kPa (1195 - 1293 psi) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 4968 Power Steering Pump: Description and Operation TTA Power Steering Pump On all vehicles equipped with power steering, the hydraulic pressure for operation of the power steering gear is provided by a belt driven power steering pump. The TTA power steering pump is a constant flow rate and displacement, vane type pump. In the event of a power steering pump drive belt failure, manual steering control of the vehicle can still be maintained. However, under these conditions, steering effort will be significantly increased. All vehicles equipped with power steering use a remote mounted reservoir for the power steering fluid. The power steering fluid remote reservoir is mounted to the rear of the cylinder head on the passenger side of the vehicle. The service procedures for the TTA power steering pump are limited to the areas and components listed below. No repair procedures are to be done on internal components of the TTA power steering pumps. - Repair of power steering fluid leaks from areas of the power steering pump sealed by O-rings is allowed. However power steering pump shaft seal leakage will require replacement of the pump. - Power steering fluid reservoirs, related components and attaching hardware. - Power steering fluid reservoir filler cap/dipstick assemblies. Because of unique shaft bearings, flow control levels or pump displacements, power steering pumps may be used only on specific vehicle applications. Be sure that all power steering pumps are only replaced with a pump that is the correct replacement for that specific application. Hydraulic pressure is provided for operation of the power steering gear by the belt driven power steering pump id. It is a constant displacement, vane type pump. The power steering pump is connected to the steering gear by a power steering fluid pressure hose and return hose. Rectangular pumping vanes in the shaft driven rotor, move power steering fluid from the intake to the cam ring pressure cavities of the power steering pump. As the rotor begins to turn, centrifugal force throws the vanes against the inside surface of the cam ring to pickup residual oil. This oil is then forced into the high pressure area. As more oil is picked up by the vanes, the additional oil is forced into the cavities of the thrust plate through two crossover holes in the cam ring and pressure plate. The crossover holes empty into the high pressure area between the pressure plate and the housing end cover. As the high pressure area is filled, oil flows under the vanes in the rotor slots, forcing the vanes to follow the inside surface of the cam ring. As the vanes reach the restricted area of the cam ring, oil is forced out from between the vanes. When excess oil flow is generated during high-speed operation, a regulated amount of oil returns to the pump intake side through a flow control valve. The flow control valve reduces the power required to drive the pump and holds down temperature build-up. When steering conditions exceed maximum pressure requirements, such as when the wheels are turned against the stops. The pressure built up in the steering gear exerts pressure on the spring end of the flow control valve. The high pressure lifts the relief valve ball from its seat and allows oil to flow through a trigger orifice located in the outlet fitting. This reduces pressure on the spring end of the flow control valve which then opens and allows the oil to return to the intake side of the pump. This action limits maximum pressure output of the pump to a safe level. Under normal power steering pump operating conditions, pressure requirements of the pump are below maximum, causing the pressure relief valve to remain closed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement Power Steering Pump: Service and Repair Power Steering Pump Flow Control Valve Seal Replacement NOTE: The power steering pump does not require removal from the engine for removal and replacement of the flow control valve fitting O-Ring. REMOVE 1. Remove the power steering fluid pressure hose from the power steering pump pressure fitting. 2. Remove the flow control valve fitting from the power steering pump housing. Prevent flow control valve and spring from sliding out of housing bore. 3. Remove and discard O-ring seal from fitting. INSTALL 1. If necessary, clean and install flow control valve and spring in pump housing bore. 2. Install new O-ring seal on fitting. 3. Install fitting in pump housing and tighten to 75 Nm (55 ft. lbs.). 4. Install power steering fluid pressure hose on flow control valve fitting. 5. Position locating pin on power steering pressure hose banjo fitting so it is against power steering pump mounting bracket. While holding locating pin against power steering pump bracket, torque banjo bolt to 34 Nm (25 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 4971 Power Steering Pump: Service and Repair Power Steering Pump Initial Operation CAUTION: The fluid level should be checked with engine off to prevent injury from moving components. Use only Mopar (R) Power Steering Fluid. Do not use automatic transmission fluid. Do not overfill. Wipe filler cap clean, then check the fluid level. The dipstick should indicate FULL COLD when the fluid is at normal temperature of approximately 21° C - 27°C (70°F - 80°F). 1. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. 2. Start the engine and let run for a few seconds. Then turn the engine off. 3. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 4. Raise the front wheels off the ground. 5. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 6. Add power steering fluid if necessary. 7. Lower the vehicle and turn the steering wheel slowly from lock to lock. 8. Stop the engine. Check the fluid level and refill as required. 9. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 4972 Power Steering Pump: Service and Repair Power Steering Pump Mounting Bracket Replacement DISASSEMBLE 1. Remove power steering pump from engine. CAUTION: Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley. This will damage the pulley and the power steering pump. 2. Mount the power steering pump in a vise using the power steering pump mounting bracket. Mount Puller, Special Tool C-4333 or C-4068 on power steering pump pulley. Remove the power steering pump pulley from the power steering pump shaft. 3. Remove the 3 bolts attaching the power steering pump to the mounting bracket. 4. Remove power steering pump from mounting bracket. ASSEMBLE 1. Install power steering pump on mounting bracket. Install the 3 power steering pump mounting bolts. Torque the 3 mounting bolts to 54 Nm (40 ft. lbs.). CAUTION: Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley. This will damage the pulley and the power steering pump. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 4973 2. Place power steering pump pulley squarely on end of power steering pump shaft. Mount Installer, Special Tool C-4063 in internal threads of the power steering pump shaft and against power steering pump pulley. 3. Ensuring that special tool and pulley remain aligned with pump shaft, force pulley onto power steering pump shaft until flush with the end of the shaft. When pulley is flush with shaft tool will no longer be able to be turned. 4. Remove Installer, Special Tool C-4063 from power steering pump. 5. Install power steering pump and bracket assembly back on engine. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 4974 Power Steering Pump: Service and Repair Power Steering Pump Pulley Replacement NOTE: The power steering pump must be removed from the vehicle for removal of the power steering pump pulley. REMOVE 1. Remove power steering pump from engine. CAUTION: Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley. This will damage the pulley and the power steering pump. 2. Mount power steering pump in a vise using the power steering pump mounting bracket. Install Puller, Special Tool C-4333 or C-4068, or equivalents on power steering pump pulley. Remove the power steering pump pulley from the power steering pump shaft. 3. Replace power steering pump pulley if bent, cracked, or loose. CAUTION: Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley. This will damage the pulley and the power steering pump. INSTALL 1. Mount power steering pump in a vise using the power steering pump mounting bracket. Then place power steering pump pulley squarely on end of power steering pump shaft. Mount Installer, Special Tool C-4063, or equivalent in internal threads of the power steering pump shaft and against power steering pump pulley. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 4975 2. Ensuring that special tool and pulley remain aligned with pump shaft, force pulley onto power steering pump shaft until flush with the end of the shaft. When pulley is flush with shaft tool will no longer be able to be turned. 3. Remove Installer, Special Tool C-4063, or equivalent from power steering pump. 4. Install power steering pump and mounting bracket back on engine. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 4976 Power Steering Pump: Service and Repair Power Steering Pump Flow Control Valve Seal Replacement NOTE: The power steering pump does not require removal from the engine for removal and replacement of the flow control valve fitting O-Ring. REMOVE 1. Remove the power steering fluid pressure hose from the power steering pump pressure fitting. 2. Remove the flow control valve fitting from the power steering pump housing. Prevent flow control valve and spring from sliding out of housing bore. 3. Remove and discard O-ring seal from fitting. INSTALL 1. If necessary, clean and install flow control valve and spring in pump housing bore. 2. Install new O-ring seal on fitting. 3. Install fitting in pump housing and tighten to 75 Nm (55 ft. lbs.). 4. Install power steering fluid pressure hose on flow control valve fitting. 5. Position locating pin on power steering pressure hose banjo fitting so it is against power steering pump mounting bracket. While holding locating pin against power steering pump bracket, torque banjo bolt to 34 Nm (25 ft. lbs.). Power Steering Pump Initial Operation CAUTION: The fluid level should be checked with engine off to prevent injury from moving components. Use only Mopar (R) Power Steering Fluid. Do not use automatic transmission fluid. Do not overfill. Wipe filler cap clean, then check the fluid level. The dipstick should indicate FULL COLD when the fluid is at normal temperature of approximately 21° C - 27°C (70°F - 80°F). 1. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. 2. Start the engine and let run for a few seconds. Then turn the engine off. 3. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 4. Raise the front wheels off the ground. 5. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 6. Add power steering fluid if necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 4977 7. Lower the vehicle and turn the steering wheel slowly from lock to lock. 8. Stop the engine. Check the fluid level and refill as required. 9. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. Power Steering Pump Mounting Bracket Replacement DISASSEMBLE 1. Remove power steering pump from engine. CAUTION: Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley. This will damage the pulley and the power steering pump. 2. Mount the power steering pump in a vise using the power steering pump mounting bracket. Mount Puller, Special Tool C-4333 or C-4068 on power steering pump pulley. Remove the power steering pump pulley from the power steering pump shaft. 3. Remove the 3 bolts attaching the power steering pump to the mounting bracket. 4. Remove power steering pump from mounting bracket. ASSEMBLE 1. Install power steering pump on mounting bracket. Install the 3 power steering pump mounting bolts. Torque the 3 mounting bolts to 54 Nm (40 ft. lbs.). CAUTION: Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley. This will damage the pulley and the power steering pump. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 4978 2. Place power steering pump pulley squarely on end of power steering pump shaft. Mount Installer, Special Tool C-4063 in internal threads of the power steering pump shaft and against power steering pump pulley. 3. Ensuring that special tool and pulley remain aligned with pump shaft, force pulley onto power steering pump shaft until flush with the end of the shaft. When pulley is flush with shaft tool will no longer be able to be turned. 4. Remove Installer, Special Tool C-4063 from power steering pump. 5. Install power steering pump and bracket assembly back on engine. Power Steering Pump Pulley Replacement NOTE: The power steering pump must be removed from the vehicle for removal of the power steering pump pulley. REMOVE 1. Remove power steering pump from engine. CAUTION: Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley. This will damage the pulley and the power steering pump. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 4979 2. Mount power steering pump in a vise using the power steering pump mounting bracket. Install Puller, Special Tool C-4333 or C-4068, or equivalents on power steering pump pulley. Remove the power steering pump pulley from the power steering pump shaft. 3. Replace power steering pump pulley if bent, cracked, or loose. CAUTION: Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley. This will damage the pulley and the power steering pump. INSTALL 1. Mount power steering pump in a vise using the power steering pump mounting bracket. Then place power steering pump pulley squarely on end of power steering pump shaft. Mount Installer, Special Tool C-4063, or equivalent in internal threads of the power steering pump shaft and against power steering pump pulley. 2. Ensuring that special tool and pulley remain aligned with pump shaft, force pulley onto power steering pump shaft until flush with the end of the shaft. When pulley is flush with shaft tool will no longer be able to be turned. 3. Remove Installer, Special Tool C-4063, or equivalent from power steering pump. 4. Install power steering pump and mounting bracket back on engine. Installation Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 4980 1. Install power steering pump and mounting bracket as an assembly back on the engine using reverse of removal procedure. 2. Slide front power steering pump bracket between bracket mounting bolt and front engine mount. Be sure washer on bolt is between the head of the bolt and bracket and does not get trapped between bracket and engine mount. 3. Install the 2 power steering pump to cast mounting bracket attaching bolts. Do not tighten bolts at this time. 4. Install power steering pump drive belt on power steering pump pulley. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 4981 5. Install a 1/2 inch breaker bar in the square hole in the front power steering pump mounting bracket. Then rotate pump in to obtain the correct drive belt tension. When correct drive belt tension is obtained torque the 2 bolts at the power steering pump cast mounting bracket to 54 Nm (40 ft. lbs.) . Then torque the front power steering pump mounting bracket bolt to 54 Nm (40 ft. lbs.). 6. Install power steering supply hose on power steering pump suction fitting. Install hose clamp on hose, being sure hose clamp is installed on hose past upset bead on power steering pump tube. 7. Using a lint free towel, wipe clean all open power steering hose ends, and power steering pump fittings. 8. Install a new O-ring on the end of the power steering pressure hose banjo fitting. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 4982 9. Install a new O-ring on power steering fluid pressure hose banjo fitting bolt. 10. Lubricate both O-rings using fresh clean power steering fluid. 11. Install banjo bolt into the power steering pressure hose banjo fitting. 12. Attach power steering pressure hose on outlet fitting of the power steering pump. 13. Position locating pin on power steering pressure hose banjo fitting so it is against power steering pump mounting bracket. While holding locating pin against power steering pump bracket, torque pump end Banjo bolt to 34 Nm (25 ft. lbs.). CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar (R), Power Steering Fluid, or equivalent. 14. Fill power steering reservoir to correct fluid level. 15. Connect negative cable back on negative post of battery. 16. Start the engine and let run for a few seconds. Then turn the engine off. 17. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 18. Raise front wheels of vehicle off the ground. 19. Start engine, then slowly turn steering wheel right and left several times until lightly contacting the wheel stops. Then turn the engine off. 20. Add power steering fluid if necessary. 21. Lower the vehicle. Start engine again and turn the steering wheel slowly from lock to lock. 22. Stop the engine. Check the fluid level and refill as required 23. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. 24. After power steering pump is installed, check for leaks at all hose connections and power steering pump fittings. Removal WARNING: Power steering oil, engine components and exhaust system may be extremely hot if engine has been running. Do not start engine with any loose or disconnected hoses, or allow hoses to touch hot exhaust manifold or catalyst. The power steering pump removal procedure and pump and bracket fastener locations are the same for both engine applications used for this vehicle. The front power steering pump bracket must be removed as an assembly with the power steering pump and removed from the pump after removing the pulley from the power steering pump. 1. Remove battery cable from (-) negative post on battery. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 4983 2. Remove Banjo Bolt and power steering fluid pressure hose from pressure fitting on power steering pump. 3. Discard all used O-rings on the power steering pressure hose Banjo fitting and Banjo bolt. 4. Remove hose clamp attaching power steering fluid supply hose to the power steering pump suction fitting. Remove power steering fluid supply hose from power steering pump fitting. 5. Raise vehicle on jackstands or centered on a frame contact type hoist. NOTE: If the vehicle is equipped with a dual overhead cam engine, the bolt attaching the coolant tube to the intake manifold needs to be removed. Refer to following step for required procedure. 6. Remove the bolt attaching the coolant tube to the bottom of the intake manifold. The bolt requires removal to allow the coolant tube to be moved out of the way for access to the power steering pump mounting bolt. The coolant tube does not need to be removed or the cooling system drained. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 4984 7. Remove the 2 power steering pump to cast bracket mounting and adjustment bolts. NOTE: The power steering pump front mounting bracket is slotted at the bolt attaching it to the front engine mount. This bolt only needs to be loosened to remove mounting bracket from engine. 8. Loosen bolt attaching the power steering pump front mounting to the front engine mount only far enough to slide the bracket out from under the bolt. 9. Remove power steering pump drive belt from power steering pump pulley. 10. Remove power steering pump and front mounting bracket as an assembly from the engine. 11. Transfer required parts from removed power steering pump to replacement power steering pump. Suction Port Seal Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 4985 NOTE: The power steering pump does not require removal from the engine for removal and replacement of the suction port O-Ring seal. REMOVE 1. Remove power steering fluid supply hose from power steering pump suction port fitting. 2. Remove bolt attaching power steering pump suction port fitting to the power steering pump. 3. Remove the suction port fitting from the power steering pump. 4. Remove and discard O-ring seal from suction port fitting. INSTALL 1. Install new O-ring seal on suction fitting. 2. Install suction port fitting in power steering pump. Install and securely tighten the suction port fitting attaching bolt. 3. Install power steering fluid supply hose on suction port fitting, being sure hose clamp is installed on hose past upset bead on suction port fitting. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 4991 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 4992 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 4993 Power Steering Pressure Switch: Description and Operation Fig. 15 Power Steering Pressure Switch PURPOSE On vehicles equipped with power steering, a power steering pressure switch is used to improve the vehicle's idle quality. The pressure switch improves vehicle idle quality, by controlling engine idle speed when required. The switch (Fig. 15) provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. OPERATION The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed is increased. This increase in engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. When power steering pump pressure exceeds 2,758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. The power steering pressure switch is mounted directly to the power steering gear on vehicles requiring its usage. CIRCUIT OPERATION The power steering pressure switch opens and closes circuit K10 between the Powertrain Control Module (PCM) and ground. Circuit K10 connects to cavity 45 of the PCM connector. Circuit Z12 provides ground for the power steering pressure switch. The grounding point for circuit Z12 is the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 4994 Power Steering Pressure Switch: Service and Repair CAUTION: When removing and installing the power steering pressure switch, the use of a 7/8 inch deep well socket is required. The deep well socket will prevent damage to the plastic, electrical connector area, of the power steering pressure switch. REMOVE 1. Disconnect negative battery cable from the negative post of the battery. Be sure cable is isolated from negative post on battery. 2. Raise vehicle. 3. Locate power steering pressure switch on back side of power steering gear. 4. Remove vehicle wiring harness connector, from power steering pressure switch. 5. Remove power steering pressure switch, from power steering gear. CAUTION: When tightening the power steering pressure switch after installation in steering gear, do not exceed the torque specification shown in step 1 below. Over-tightening may result in stripping the threads out of the pressure switch port on the steering gear. INSTALL 1. Install power steering pressure switch into power steering gear by hand until fully seated. Then torque power steering pressure switch to 8 Nm (70 inch lbs.). 2. Install vehicle wiring harness connector onto power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with locking tab on power steering pressure switch. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar (R), Power Steering Fluid, or equivalent. 3. Fill power steering reservoir to correct fluid level. 4. Connect negative cable back on negative post of battery. 5. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components . Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 5000 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming 1. Verify that the negative battery cable is disconnected and isolated. 2. Connect scan tool (DRB) to Data Link connector, located at right side of the steering column and at the lower edge of the lower instrument panel. 3. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 4. After checking that no one is inside the vehicle, connect the battery negative terminal. 5. Using the scan tool, read and record active diagnostic code data. 6. Read and record any stored diagnostic codes. 7. Refer to the airbag system Diagnostic Test if any diagnostic codes are found in Step 5 or Step 6. 8. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the airbag system Diagnostic Test. If the airbag warning lamp either fails to light with the ignition switch ON, or the light goes on and stays on, there is a system malfunction. Refer to the airbag system Diagnostic Test. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair Steering Column Cover: Service and Repair REMOVAL Instrument Panel Assembly 1. Remove the three attachment screws along the bottom of the cover and screw on the left outward face of cover. 2. Grasp the cover and pull rearward until the clips disengage. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest for Steering Gear: > 19-04-96A > Jan > 97 > Steering Gear - Whistle/Hiss On Right Turns Steering Gear: Customer Interest Steering Gear - Whistle/Hiss On Right Turns NO: 19-04-96 Rev. A GROUP: Steering EFFECTIVE DATE: Jan. 10, 1997 SUBJECT: Steering Noise When Turning Right THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-04-96, DATED AUGUST 9, 1996 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE NEON HAS BEEN ADDED. ALL CHANGES TO THE PROCEDURE ARE MARKED WITH **ASTERISKS** MODELS: 1995 - 1996 (JA) Breeze/Cirrus/Stratus **1995 - 1997 (PL/1) Neon** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH STANDARD STEERING, SALES CODE SBA. SYMPTOM/CONDITION: Whistle and/or hiss noise from steering gear when making right turns. DIAGNOSIS: To verify noise, heat the power steering fluid to 155-165° F by holding engine speed at 2000-3000 rpm. Turn the steering wheel to the left and hit the stop ten times. Turn the wheel to the right and hit the stop ten times. Repeat this for a total of three times. Return the steering wheel to the center position and let the engine idle. Very slowly, turn the wheel to the right. Periodically stop and move the wheel back very slowly. Listen for a high pitched "whistle". If a "whistle" exists it can be maintained by holding the wheel at that position. Return the wheel to the center position. Turn the wheel to the right at a speed of approximately 12 rpm. Listen for a constant "hiss" noise. If either of these noises exists during right hand turns, perform the Repair Procedure. PARTS REQUIRED: 1 04886335AA Gear Assembly, Power Steering (Breeze/Cirrus/Stratus) **1 04897187AA Gear Assembly, Power Steering (Neon)** REPAIR PROCEDURE: This bulletin involves replacing the power steering gear with a revised part. Remove and replace the power steering gear as described on page 19-36 of the 1996 Breeze/Cirrus/Stratus Service Manual (Publication No. 81-270-6121). **For Neon refer to the 1997 Neon Service Manual (Publication No. 81-270-7025) beginning on page 19-29.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-93 2.7 Hrs. 1995-1996 (Breeze/Cirrus/Stratus) 19-00-02-93 1.8 Hrs. 1995-1997 (Neon) FAILURE CODE: 68 - Noisy Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-04-96A > Jan > 97 > Steering Gear - Whistle/Hiss On Right Turns Steering Gear: All Technical Service Bulletins Steering Gear - Whistle/Hiss On Right Turns NO: 19-04-96 Rev. A GROUP: Steering EFFECTIVE DATE: Jan. 10, 1997 SUBJECT: Steering Noise When Turning Right THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-04-96, DATED AUGUST 9, 1996 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE NEON HAS BEEN ADDED. ALL CHANGES TO THE PROCEDURE ARE MARKED WITH **ASTERISKS** MODELS: 1995 - 1996 (JA) Breeze/Cirrus/Stratus **1995 - 1997 (PL/1) Neon** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH STANDARD STEERING, SALES CODE SBA. SYMPTOM/CONDITION: Whistle and/or hiss noise from steering gear when making right turns. DIAGNOSIS: To verify noise, heat the power steering fluid to 155-165° F by holding engine speed at 2000-3000 rpm. Turn the steering wheel to the left and hit the stop ten times. Turn the wheel to the right and hit the stop ten times. Repeat this for a total of three times. Return the steering wheel to the center position and let the engine idle. Very slowly, turn the wheel to the right. Periodically stop and move the wheel back very slowly. Listen for a high pitched "whistle". If a "whistle" exists it can be maintained by holding the wheel at that position. Return the wheel to the center position. Turn the wheel to the right at a speed of approximately 12 rpm. Listen for a constant "hiss" noise. If either of these noises exists during right hand turns, perform the Repair Procedure. PARTS REQUIRED: 1 04886335AA Gear Assembly, Power Steering (Breeze/Cirrus/Stratus) **1 04897187AA Gear Assembly, Power Steering (Neon)** REPAIR PROCEDURE: This bulletin involves replacing the power steering gear with a revised part. Remove and replace the power steering gear as described on page 19-36 of the 1996 Breeze/Cirrus/Stratus Service Manual (Publication No. 81-270-6121). **For Neon refer to the 1997 Neon Service Manual (Publication No. 81-270-7025) beginning on page 19-29.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-93 2.7 Hrs. 1995-1996 (Breeze/Cirrus/Stratus) 19-00-02-93 1.8 Hrs. 1995-1997 (Neon) FAILURE CODE: 68 - Noisy Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 5017 Steering Gear: Specifications Attaching Bolts ..................................................................................................................................... .................................................... 68 Nm (50 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 5018 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 5019 Steering Gear: Service Precautions NOTE: The power steering gear should NOT be serviced or adjusted. If a malfunction or oil leak occurs with the steering gear, the complete steering gear needs to be replaced. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 5020 Steering Gear: Description and Operation The power steering system consists of these four major components. Power Steering Gear, Power Steering Pump, Pressure Hose, and Return Line. Turning of the steering wheel is converted into linear travel through the meshing of the helical pinion teeth with the rack teeth. Power assist steering is provided by an open center, rotary type control valve which directs oil from the pump to either side of the integral rack piston. Road feel is controlled by the diameter of a torsion bar which initially steers the vehicle. This movement directs oil behind the integral rack piston, which, in turn, builds up hydraulic pressure and assists in the turning effort. The drive tangs on the pinion of the power steering pump mate loosely with a stub shaft. This is to permit manual steering control to be maintained if the drive belt on the power steering pump should break. However, under these conditions, steering effort will be increased. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 5021 Steering Gear: Testing and Inspection GENERAL INFORMATION The following procedure can be used to test the operation of the power steering system on the vehicle. This test will provide the flow rate of the power steering pump along with the maximum relief pressure. This test is to be performed any time a power steering system problem is present to determine if the power steering pump or power steering gear is not functioning properly. The following pressure and flow test is performed using Pressure/Flow Tester, Special Tool 6815, or equivalent. TEST PROCEDURE 1. Check power steering pump drive belt tension and adjust as necessary. 2. Disconnect power steering fluid pressure hose, at power steering pump. Use a container for dripping fluid. 3. Connect Pressure Gauge, Special Tool from kit 6815, or equivalent to both hoses using adapter fittings. Connect spare pressure hose, to power steering pump pressure hose banjo fitting. 4. Completely open valve on Special Tool 6815, or equivalent. 5. Start engine and let idle long enough to circulate power steering fluid through flow/pressure test and get air out of fluid. Then shut off engine. 6. Check power steering fluid level, and add fluid as necessary. Start engine again and let idle. 7. Pressure gauge should read below 862 kPa (125 psi), if above, inspect the hoses for restrictions and repair as necessary. The initial pressure reading should be in the range of 345 - 552 kPa (50 - 80 psi). The flow meter should read between 1.3 - 1.4 GPM. CAUTION: The following test procedure involves testing power steering pump maximum pressure output and flow control valve operation. Do not leave valve closed for more than 5 seconds as the pump could be damaged. 8. Close valve fully three times and record highest pressure indicated each time. All three readings must be above specifications and within 345 kPa (50 psi) of each other. NOTE: Power steering pump maximum relief pressure is 8240 to 8920 kPa (1195 to 1293 psi). If power steering pump pressures above specifications but not within 345 kPa (50 psi) of each other, then replace power steering pump. - If pressures within 345 kPa (50 psi) of each other but below specifications, then replace power steering pump. CAUTION: Do not force the pump to operate against the stops for more than 5 seconds at a time because, pump damage will result. 9. Open test valve. Turn steering wheel to the extreme left and right positions until against the stops, recording the highest indicated pressure at each position. Compare pressure gauge readings to power steering pump specifications. If highest output pressures are not the same against either stop, the steering gear is leaking internally and must be replaced. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal Steering Gear: Service and Repair Removal 1. From interior of vehicle, disconnect the steering gear coupler, from the steering column shaft coupler. 2. Raise vehicle on jack stands or centered on a frame contact type hoist. 3. Remove both front wheel and tire assemblies from the vehicle. 4. Remove engine/transaxle bobble dampener, on vehicles so equipped, from front suspension crossmember. Bobble strut does not need to be removed from transaxle assembly. 5. Remove nuts attaching both outer tie rod ends to the steering knuckles. Nuts are to be removed from tie rod ends using the following procedure, hold tie rod end stud with an 11/32 socket, while loosening and removing nut with wrench. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5024 Tie Rod End Removal From Steering Knuckle 6. Remove both tie rod end studs, from the steering knuckles, using Remover, Special Tool MB-990635, or equivalent. 7. If equipped, remove vehicle wiring harness connector from the power steering fluid pressure switch. 8. If vehicle is equipped with power steering, remove power steering pressure and return hose routing bracket from front suspension crossmember. The hose routing bracket does not have to be removed from the power steering pressure and return hoses. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5025 9. If vehicle is equipped with power steering, remove power steering fluid, pressure and return hoses from the power steering gear assembly. NOTE: This vehicle is designed and assembled using NET BUILD front suspension alignment settings. This means that front suspension alignment settings are determined as the vehicle is designed by the location of front suspension components in relation to the vehicle body. This process is carried out when building the vehicle, by accurately locating the front suspension crossmember, to master gage holes located in the underbody of the vehicle. With this method of designing and building a vehicle, it is no longer possible to adjust a vehicles front suspension alignment settings to the required specifications. Due to this, whenever the front suspension crossmember is removed from a vehicle, it MUST be replaced in the same location on the body of the vehicle it was removed from. Front suspension Toe settings though are still adjustable by the outer tie rod ends. CAUTION: Before removing front suspension crossmember from the vehicle, the location of the front suspension crossmember MUST be scribed on body of vehicle per. This must be done so crossmember can be relocated against body of vehicle in the same location when it is reinstalled. If location of front suspension crossmember to body of vehicle is not maintained when vehicle is assembled, NET BUILD front suspension alignment settings will not be obtained. This may lead to handling and or tire wear problems. 10. Using an awl, scribe a line marking the location of where front suspension crossmember is mounted against the body of the vehicle. 11. Position a transmission jack under the center of the front suspension crossmember. Transmission jack is used to lower, support and raise front Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5026 suspension crossmember when removing steering gear assembly. 12. Loosen and fully remove the front 2 bolts attaching front suspension crossmember to frame rails of vehicle. Then loosen the 2 rear bolts attaching front suspension crossmember and lower control arm to body of vehicle. Lower front suspension crossmember while loosening rear bolts, but do not remove rear bolts from crossmember. 13. Using transmission jack, lower front suspension crossmember enough to allow steering gear to be removed from crossmember. When lowering front suspension crossmember, do not let crossmember hang from lower control arms weight of crossmember should be supported by transmission jack. 14. Loosen and remove the 4 bolts, attaching steering assembly to front suspension crossmember. Then remove the steering gear assembly from the front suspension crossmember. 15. Transfer required parts from removed steering gear assembly to the replacement steering gear, new steering gear is being installed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5027 Steering Gear: Service and Repair Installation 1. Install steering gear assembly on front suspension crossmember. Install the 4 steering gear assembly to front crossmember mounting bolts. Torque the 4 steering gear mounting bolts to 68 Nm (50 ft. lbs.). 2. Using the transmission jack, raise front suspension crossmember and steering gear against body and frame rails of vehicle. Start the 2 rear bolts into tapping plates, attaching front suspension crossmember to body of vehicle. Then install the 2 front bolts, attaching front suspension crossmember to frame rails of vehicle Tighten the 4 mounting bolts, until front suspension crossmember is against body of vehicle at the 4 mounting points. Then torque the 4 mounting bolts to 2 Nm (20 inch lbs.) to hold front suspension crossmember in position. CAUTION: When front suspension crossmember is installed back in vehicle, crossmember MUST be aligned with positioning marks previously scribed into body of vehicle. This MUST be done to maintain NET BUILD front suspension alignment settings. 3. Using a soft face hammer, tap front suspension crossmember into position, until it is aligned with the 2 previously scribed positioning marks on body of vehicle. When front suspension crossmember is correctly positioned, torque the 2 rear crossmember/lower control arm mounting bolts to 163 Nm (120 ft. lbs.). Then torque the 2 front crossmember to frame rail attaching bolts to 163 Nm (120 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5028 4. If vehicle is equipped with power steering, install power steering fluid pressure and return hoses into correct fluid ports on power steering gear assembly. Torque power steering fluid pressure and return lines to steering gear tube nuts to 31 Nm (275 inch lbs.). 5. If vehicle is equipped with power steering, install power steering pressure and return hose routing bracket and attaching screw on front suspension crossmember. Torque hose routing bracket to crossmember attaching bolt to 23 Nm (17 ft. lbs.). 6. If the vehicle is equipped with power steering, install vehicle wiring harness connector onto power steering fluid pressure switch on steering gear assembly. Be sure locking tab on wiring harness connector is securely latched to pressure switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5029 7. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket, torque tie rod end attaching nut to 55 Nm (40 ft. lbs.). 8. Install engine/transaxle bobble strut back on front suspension crossmember bracket. Install and securely tighten the dampener to crossmember attaching bolt. 9. Install the wheel and tire assemblies back on vehicle. Tighten the wheel nuts to 135 Nm (100 ft. lbs.) torque. 10. Lower vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5030 11. From interior of vehicle, reconnect the steering gear coupler with the steering column shaft coupler. Install steering gear coupler retaining pinch bolt and torque to 28 Nm (250 inch lbs.). Be sure to install the upper to lower steering couplet retaining bolt, retention pin. CAUTION: Do not use automatic transmission fluid. 12. Fill power steering pump fluid reservoir to the (Full-Cold) proper level. 13. Start the engine and let run for a few seconds. Then turn the engine off. 14. Add fluid if necessary. 15. Raise front wheels of vehicle off the ground. 16. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Fill pump reservoir to correct level with Mopar (R), Power Steering Fluid, or equivalent. 17. Lower front wheels of vehicle back on the ground. CAUTION: During this procedure do not allow the steering gear inner tie rod boots to become twisted. 18. Adjust the front Toe setting on the vehicle. Refer to Alignment. Outer Tie Rod End Jam Nut 19. Tighten tie rod jam nut to 61 Nm (45 ft. lbs.) torque. 20. Adjust steering gear to tie rod boots at tie rods. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Description and Operation Steering Shaft Coupler: Description and Operation This vehicle uses a differently designed coupling for connecting the steering column to the steering gear. This coupling is different in its appearance and in the way it functions than the previous coupling used on this vehicle and couplings used on other Chrysler vehicles. This coupling functions by bending at the bellows section of the coupling on impact, where as the previous coupling separated at its detachable joint on an impact. This coupling incorporates a hollow convoluted tube which allows the coupling to bend as required when a vehicle is involved in a collision. The previous coupling used on this vehicle incorporated 2 release washers which allowed the coupling to separate into 2 pieces, if necessary, when a vehicle was involved in a collision. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Description and Operation > Page 5034 Steering Shaft Coupler: Testing and Inspection GENERAL INFORMATION The steering column coupling MUST be inspected whenever a vehicle is involved in an impact or whenever any of the following conditions exist. 1. The steering column coupling must be inspected whenever a vehicle is involved in a collision which deploys the air bag, regardless of the extent of damage done to the vehicle. 2. If a vehicle is involved in an impact of the vehicles front suspension or under carriage, which results in any type of damage to the front suspension crossmember. 3. Under any conditions which result in the steering column assembly or steering column shaft receiving a force great enough to move the steering column or shaft forward or rearward in a vehicle. INSPECTION PROCEDURE 1. Remove the pinch bolt safety pin from the steering column shaft coupling pinch bolt. 2. Loosen the coupling pinch bolt retaining nut and remove pinch bolt from steering coupler. (Pinch bolt nut is caged to coupler and is not removable.) Then separate the steering column shaft coupling from the steering column to steering gear coupling. 3. Remove the silencer seal enclosing the steering column coupling. 4. Inspect steering column coupling in the following areas for signs of damage: - Inspect the sealing collar on the steering column coupling to ensure the it is not cracked, broken, or otherwise damaged requiring coupling replacement. - Inspect the convoluted section of the steering column coupling for the following conditions or any other visible signs of damage. Uneven spacing between the convolutes on the coupling. - Dings or dents in the convolutes of the coupling or anywhere else on the coupling wall. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Description and Operation > Page 5035 - A bend in the convoluted section of the coupling. NOTES: If any of the preceding conditions exist the steering coupling MUST be replaced. - The steering gear must be removed from the vehicle to allow access for replacement of the steering coupling. 5. If steering coupling does not require replacement, install steering column coupling silencer seal back on vehicle. 6. Ensure front wheels of vehicle are positioned straight-ahead and then align and attach steering column to steering coupling. Install the coupling pinch bolt. Tighten the pinch bolt nut to a torque of 28 Nm (250 inch lbs.). Be sure to install upper to lower steering coupling pinch bolt safety pin. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 19-02-99A > Oct > 99 > Steering Wheel/Steering Column Clunking Or Rattle Technical Service Bulletin # 19-02-99A Date: 991022 Steering Wheel/Steering Column - Clunking Or Rattle NUMBER: 19-02-99 Rev. A GROUP: Steering DATE: Oct. 22, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-01-98 DATED FEBRUARY 6, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003) AND 19-02-99 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISION ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS CHANGES. SUBJECT: Clunking Or Rattle In Steering Wheel/Steering Column OVERVIEW: This bulletin involves resetting the steering column preload. MODELS: 1995 - **2000** (JA) Breeze/Cirrus/Stratus 1996 - **2000** (JX) Sebring Convertible 1995 - 2000 (PL) Neon SYMPTOM/CONDITION: Steering wheel/column clunking or rattle is more frequent while hitting bumps or on hard turns. DIAGNOSIS: Inspect steering wheel/column for any rattle or clunking noise. If symptoms exist perform the Repair Procedure. PARTS REQUIRED: 1 05015627AA Bolt, Steering Gear Coupler Retaining, PL 1 **06506112AA Bolt, Steering Gear Coupler Retaining, JA/JX** 1 **06036212AA Clip, Steering Gear Coupler Retaining, JA/JX** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-20-12-96 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. NOTE: THE VEHICLE WHEELS NEED TO BE ON THE GROUND (SUPPORTING VEHICLE WEIGHT) WHEN PERFORMING THIS REPAIR. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with a tilt steering column, adjust to the full up position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 19-02-99A > Oct > 99 > Steering Wheel/Steering Column Clunking Or Rattle > Page 5044 3. Detach the lower steering column intermediate shaft from the steering gear shaft (Figure 1). This allows the steering column preload to reset. 4. Re-attach the intermediate shaft to the steering gear using a new pinch bolt from the Parts Required section of this bulletin. Tighten the bolt to 27 N.m (240 in. lbs.). 5. Install the retaining clip/pin into the pinch bolt (Figure 1). NOTE: A NEW STEERING GEAR COUPLING PINCH BOLT MUST BE USED WHEN RE-ATTACHING THE INTERMEDIATE SHAFT TO THE STEERING GEAR. THIS BOLT HAS A LOCKING PATCH THAT IS DESTROYED WHEN THE NUT IS REMOVED. 6. Connect the battery negative cable and reset the clock. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 19-02-99A > Oct > 99 > Steering Wheel/Steering Column - Clunking Or Rattle Technical Service Bulletin # 19-02-99A Date: 991022 Steering Wheel/Steering Column - Clunking Or Rattle NUMBER: 19-02-99 Rev. A GROUP: Steering DATE: Oct. 22, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-01-98 DATED FEBRUARY 6, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003) AND 19-02-99 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISION ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS CHANGES. SUBJECT: Clunking Or Rattle In Steering Wheel/Steering Column OVERVIEW: This bulletin involves resetting the steering column preload. MODELS: 1995 - **2000** (JA) Breeze/Cirrus/Stratus 1996 - **2000** (JX) Sebring Convertible 1995 - 2000 (PL) Neon SYMPTOM/CONDITION: Steering wheel/column clunking or rattle is more frequent while hitting bumps or on hard turns. DIAGNOSIS: Inspect steering wheel/column for any rattle or clunking noise. If symptoms exist perform the Repair Procedure. PARTS REQUIRED: 1 05015627AA Bolt, Steering Gear Coupler Retaining, PL 1 **06506112AA Bolt, Steering Gear Coupler Retaining, JA/JX** 1 **06036212AA Clip, Steering Gear Coupler Retaining, JA/JX** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-20-12-96 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. NOTE: THE VEHICLE WHEELS NEED TO BE ON THE GROUND (SUPPORTING VEHICLE WEIGHT) WHEN PERFORMING THIS REPAIR. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with a tilt steering column, adjust to the full up position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 19-02-99A > Oct > 99 > Steering Wheel/Steering Column - Clunking Or Rattle > Page 5050 3. Detach the lower steering column intermediate shaft from the steering gear shaft (Figure 1). This allows the steering column preload to reset. 4. Re-attach the intermediate shaft to the steering gear using a new pinch bolt from the Parts Required section of this bulletin. Tighten the bolt to 27 N.m (240 in. lbs.). 5. Install the retaining clip/pin into the pinch bolt (Figure 1). NOTE: A NEW STEERING GEAR COUPLING PINCH BOLT MUST BE USED WHEN RE-ATTACHING THE INTERMEDIATE SHAFT TO THE STEERING GEAR. THIS BOLT HAS A LOCKING PATCH THAT IS DESTROYED WHEN THE NUT IS REMOVED. 6. Connect the battery negative cable and reset the clock. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 5051 Steering Wheel: Specifications Retaining Nut ....................................................................................................................................... ..................................................... 61 Nm (45 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications To Steering Knuckle Nut ...................................................................................................................... .................................................... 55 Nm (40 ft. lbs.) Jam Nut ............................................................. ........................................................................................................................................ 61 Nm (45 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Page 5056 Tie Rod End: Service and Repair REMOVAL 1. Loosen the inner tie rod to outer tie rod jam nut. 2. Remove the nut attaching the outer tie rod end to steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with wrench. 3. Remove the tie rod end stud from steering knuckle arm, using Remover, Special Tool MB-990635, or equivalent. 4. Remove the outer tie rod end from the inner tie rod by unthreading it from the inner tie rod. INSTALLATION 1. Install outer tie rod onto inner tie rod. Make sure jam nut is on inner tie rod. 2. Do not tighten jam nut. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Page 5057 3. Install the tie rod end into the steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket, torque the tie rod end attaching nut to 61 Nm (45 ft. lbs.). CAUTION: During this procedure do not allow the steering gear boot to become twisted. 4. Adjust the front Toe setting on the vehicle. Refer to Alignment. 5. Torque the tie rod jam nut to a torque of 55 Nm (40 ft. lbs.) torque. 6. Adjust the steering gear to inner tie rod boots at inner tie rod if they became twisted during Toe adjustment. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications Nut/Bolt ................................................................................................................................................ .................................................... 95 Nm (70 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 5062 Ball Joint: Description and Operation The ball joint is pressed into the lower control arm and has a non-tapered stud with a notch for steering knuckle clamp bolt clearance. The ball joint stud is clamped and locked into the steering knuckle leg using a pinch bolt. The ball joint used on this vehicle is replaceable and if found defective can be serviced as a separate component of the lower control arm assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 5063 Ball Joint: Testing and Inspection Fig. 9 Ball Joint Wear Inspection With the weight of the vehicle resting on the road wheels. Grasp the grease fitting as shown and with no mechanical assistance or added force attempt to move the grease fitting. If the ball joint is worn the grease fitting will move easily. If movement is noted, replacement of the ball joint is recommended. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 5064 Ball Joint: Service and Repair REMOVAL 1. Using a screw driver or other suitable tool, pry seal boot off of ball joint assembly. 2. Position Receiving Cup, Special Tool 6758, or equivalent to support lower control arm while receiving ball joint assembly. Install Remover/Installer, Special Tool 6804, or equivalent in top of ball joint assembly. 3. Using arbor press, press ball joint assembly completely out of lower control arm. CAUTION: When installing ball joint in its mounting hole in lower control arm, position ball joint so notch in ball joint stud is facing the front lower control arm bushing. This will ease assembly of ball joint to steering knuckle when attempting to install pinch bolt. INSTALLATION 1. By hand, position ball joint assembly into ball joint bore of lower control arm. Be sure ball joint assembly is not cocked in the bore of the control arm, this will cause binding of the ball joint assembly, when being pressed into lower control arm. 2. Position assembly in an arbor press with Receiving Cup, Special Tool 6758, or equivalent supporting lower control arm. Then install Remover/Installer, Special Tool 6804, or equivalent on the bottom of the ball joint assembly. 3. Carefully align all pieces. Using the arbor press apply pressure against ball joint assembly, until ball joint is fully seated against bottom surface of Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 5065 lower control arm. Do not apply excessive pressure against ball joint and lower control arm. 4. Install a NEW ball joint assembly sealing boot on ball joint assembly. Install sealing boot as far as possible on ball joint assembly. CAUTION: Do not use an arbor press to install the sealing boot on the lower control arm ball joint assembly. Damage to the sealing boot can occur do to excessive pressure applied to sealing boot when being installed. 5. Position Receiving Cup, Special Tool 6758, or equivalent over sealing boot so it is aligned properly with bottom edge of sealing boot. Apply pressure BY HAND to special tool 6758, or equivalent until sealing boot is pressed squarely against top surface of lower control arm. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Control Arm Bushing: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration Control Arm Bushing: Customer Interest Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Control Arm Bushing: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 5075 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Control Arm Bushing: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 5076 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm Bushing: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration Control Arm Bushing: All Technical Service Bulletins Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm Bushing: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 5082 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm Bushing: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 5083 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Lower Control Arm Front Isolator Bushing Control Arm Bushing: Service and Repair Lower Control Arm Front Isolator Bushing NOTE: To perform the removal and replacement of the lower control arm front isolator bushing, the lower control arm must be removed from the vehicle. REMOVAL 1. Remove the lower control arm assembly from the vehicle. 2. Mount Remover/Installer, Special Tool C-4212-F, or equivalent in a vise. Install Bushing Remover, Special Tool 6804 and Bushing Receiver, Special Tool 6758 on Special Tool C-4212-F, or equivalents. 3. Install lower control arm on Special Tools assembled for removal of the front isolator bushing as shown. Be sure Special Tool 6758 is square on lower control arm and Special Tool 6804 is positioned correctly on isolator bushing. 4. Tighten screw on Remover/Installer Special Tool C-4212-F, or equivalent to press front bushing out of lower control arm. INSTALLATION 1. Mount Installer Cup, Special Tool C-4212-F on Remover/Installer, Special Tool C-4212-F, or equivalents. Then mount Bushing Installer; Special Tool 6810 on screw portion of Remover/Installer Special Tool C-4212-F, or equivalent. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Lower Control Arm Front Isolator Bushing > Page 5086 2. Start front bushing into lower control arm by hand, making sure it is square with its mounting hole in the lower control arm. Bushing is to he installed in lower control arm from the machined surface side of lower control arm bushing hole. 3. Install lower control arm as shown on Special Tools assembled for installing front isolator bushing into lower control arm. Be sure Special Tool C-4212-F, or equivalent is square on lower control arm and Special Tool 6810 is positioned correctly on isolator bushing. 4. Tighten screw on Remover/Installer Special Tool C-4212-F, or equivalent pressing front bushing into lower control arm. Continue pressing front hushing into lower control arm until special tool 6810 is sitting flush on the machined surface of the lower control arm. This will correctly position front hushing in lower control arm. 5. Install the lower control arm assembly back on the vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Lower Control Arm Front Isolator Bushing > Page 5087 Control Arm Bushing: Service and Repair Lower Control Arm Rear Isolator Bushing NOTE: Removal and installation of the lower control arm rear isolator bushing is done using an arbor press. Do not attempt to use a different procedure from that below for the removal and replacement of rear lower control arm bushing. REMOVAL 1. Remove the lower control arm assembly from the vehicle. 2. Position lower control arm in an arbor press supported at rear bushing using Receiver Cup, Special Tool 6556, or equivalent. Position Remover/Installer, Special Tool 6758, or equivalent on top of rear control arm bushing. 3. Press isolator bushing out of the lower control arm. INSTALLATION 1. Install the rear bushing into the lower control arm in the direction indicated. Rear bushing must be positioned in lower control arm with the void in the bushing pointing toward the compression strut of the lower control arm as shown. 2. Place lower control arm in an arbor press supported at rear bushing hole using Receiver Cup, Special Tool 6556, or equivalent. Correctly position Remove Installer, Special Tool 6760, or equivalent on top of rear control arm bushing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Lower Control Arm Front Isolator Bushing > Page 5088 3. Press rear bushing into lower control arm, until flange on bushing is flush with machined surface of lower control arm. 4. Install the lower control arm assembly hack on the vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well - Creak/Rattle on Bumps Technical Service Bulletin # 23-47-97 Date: 970926 Front Foot Well - Creak/Rattle on Bumps NO: 23-47-97 GROUP: Body EFFECTIVE DATE: Sept. 26, 1997 SUBJECT: Creak/Rattle From Front Foot Well MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Creak/rattle from driver or passenger front foot well. The creak/rattle is more pronounced over bumps. DIAGNOSIS: Drive the vehicle over a bumpy road and listen for a creak/rattle in the foot well area. If creak/rattle is heard proceed with the repair procedure on the side that the noise is heard. If the side the creak/rattle is coming from cannot be determined by sound, torque each crossmember bolt to 163 Nm (120 ft lbs). If the bolt was at 163 Nm (120 ft.lbs), the torque is acceptable and no further action is needed on that side. If the torque was not at 163 Nm (120 ft. lbs), proceed to the Repair Procedure. PARTS REQUIRED: AR(1) 05011650AA Crossmember Bolt/Nut Repair Kit (Right) AR(1) 05011651AA Crossmember Bolt/Nut Repair Kit (Left) Each kit will include one of the following components: Cage Nut, Crossmember Bolt, Crossmember Mastic Patch Drain Plug Access Hole Template POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-30-01-90 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves drilling an access hole to replace the crossmember bolt and cage nut, then sealing the access hole. 1. Raise vehicle to gain access to the crossmember bolt. 2. Remove the crossmember bolt. 3. Lower the vehicle and open the door. 4. Slide the seat to the full rearward position. Remove the floor mat if so equipped. 5. Remove the scuff plate and kick panel. 6. Pull the carpet and pad away to access the floor. 7. Prop the clutch and brake pedal to make room for drilling (drivers side only). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well - Creak/Rattle on Bumps > Page 5097 8. Insert the template, mark and center punch the floor pan (Figure 1). 9. Using a drill and 70 mm (2-3/4") Dia hole saw, drill in the floor to access the cage nut. 10. Pry up on the cage surrounding the nut and slide the nut out. 11. Insert the new nut and bend the cage back into position to secure the nut. 12. Raise the vehicle and install the new bolt, torque to 163 Nm (120 ft. lbs.) 13. Lower the vehicle and vacuum all drill shavings. 14. Install the drain hole plug into the hole in the floor. Use a heat gun to seal the plug to the floor. 15. Center the mastic patch over the drain hole plug and install (Figure 2). To install, remove backing paper and apply firm even pressure across the entire patch to seal. 16. Position pad and carpet into proper location. 17. Remove prop holding brake and clutch pedal if applied. 18. Install the scuff plate and kick panel. 19. Install floor mat and reposition seat. 20. Repeat procedure for other side if needed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well Creak/Rattle on Bumps Technical Service Bulletin # 23-47-97 Date: 970926 Front Foot Well - Creak/Rattle on Bumps NO: 23-47-97 GROUP: Body EFFECTIVE DATE: Sept. 26, 1997 SUBJECT: Creak/Rattle From Front Foot Well MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Creak/rattle from driver or passenger front foot well. The creak/rattle is more pronounced over bumps. DIAGNOSIS: Drive the vehicle over a bumpy road and listen for a creak/rattle in the foot well area. If creak/rattle is heard proceed with the repair procedure on the side that the noise is heard. If the side the creak/rattle is coming from cannot be determined by sound, torque each crossmember bolt to 163 Nm (120 ft lbs). If the bolt was at 163 Nm (120 ft.lbs), the torque is acceptable and no further action is needed on that side. If the torque was not at 163 Nm (120 ft. lbs), proceed to the Repair Procedure. PARTS REQUIRED: AR(1) 05011650AA Crossmember Bolt/Nut Repair Kit (Right) AR(1) 05011651AA Crossmember Bolt/Nut Repair Kit (Left) Each kit will include one of the following components: Cage Nut, Crossmember Bolt, Crossmember Mastic Patch Drain Plug Access Hole Template POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-30-01-90 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves drilling an access hole to replace the crossmember bolt and cage nut, then sealing the access hole. 1. Raise vehicle to gain access to the crossmember bolt. 2. Remove the crossmember bolt. 3. Lower the vehicle and open the door. 4. Slide the seat to the full rearward position. Remove the floor mat if so equipped. 5. Remove the scuff plate and kick panel. 6. Pull the carpet and pad away to access the floor. 7. Prop the clutch and brake pedal to make room for drilling (drivers side only). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well Creak/Rattle on Bumps > Page 5103 8. Insert the template, mark and center punch the floor pan (Figure 1). 9. Using a drill and 70 mm (2-3/4") Dia hole saw, drill in the floor to access the cage nut. 10. Pry up on the cage surrounding the nut and slide the nut out. 11. Insert the new nut and bend the cage back into position to secure the nut. 12. Raise the vehicle and install the new bolt, torque to 163 Nm (120 ft. lbs.) 13. Lower the vehicle and vacuum all drill shavings. 14. Install the drain hole plug into the hole in the floor. Use a heat gun to seal the plug to the floor. 15. Center the mastic patch over the drain hole plug and install (Figure 2). To install, remove backing paper and apply firm even pressure across the entire patch to seal. 16. Position pad and carpet into proper location. 17. Remove prop holding brake and clutch pedal if applied. 18. Install the scuff plate and kick panel. 19. Install floor mat and reposition seat. 20. Repeat procedure for other side if needed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Page 5104 Cross-Member: Specifications Attaching Bolts ..................................................................................................................................... ................................................ 163 Nm (120 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Customer Interest for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension Popping/Creaking Noises Front Steering Knuckle: Customer Interest Front Suspension - Popping/Creaking Noises NO: 02-02-97 Rev. A GROUP: Front Suspension EFFECTIVE DATE: Dec. 15, 1997 SUBJECT: Popping/Creaking Noise in Front Suspension THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-02-97 DATED FEBRUARY 28, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL FRONT SUSPENSION NOISE DIAGNOSTICS/REPAIRS HAVE BEEN ADDED. THE ADDITIONS ARE HIGHLIGHTED WITH ASTERISKS. MODELS: 1995 - 1998 (PL) Neon SYMPTOM/CONDITION: **A popping noise from the front suspension may be experienced while: ^ Going in reverse or forward with the steering wheel turned completely in one direction (parking lot maneuvers). ^ Shifting from drive to reverse, reverse to drive, etc. ^ Pulling in/out of driveway. ^ Large dips/bumps in the road such as speed bumps. ** DIAGNOSIS: If the customer describes the front suspension noise in conditions such as those described above, perform the Repair Procedure. PARTS REQUIRED: NOTE: THE 1995 NEONS BUILT IN 1994 USED 13" KNUCKLE ASSEMBLIES WITH 13" OR 14" WHEELS. LATER BUILT VEHICLES HAVE 13" OR 14" KNUCKLE ASSEMBLIES TO MATCH ORIGINAL WHEEL SIZE. TO DETERMINE THE PROPER KNUCKLE SIZE, COUNT THE STUDS ON THE HUB THEN REFER TO THE PARTS LIST PROVIDED IN THIS BULLETIN. CAUTION: DO NOT USE THE WHEEL SIZE TO DETERMINE PROPER KNUCKLE PART NUMBERS. REPAIR PROCEDURE: **This bulletin involves inspecting/replacing as needed both front wheel bearings and steering knuckles, front upper strut mounts, engine mounts, and lubing the driveshafts.** Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Customer Interest for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension Popping/Creaking Noises > Page 5113 **NOTE: USE TABLE TO DETERMINE WHICH STEPS TO PERFORM BASED ON VEHICLE BUILD DATE AND IF TECHNICAL SERVICE BULLETIN 02-02-97, DATED FEBRUARY 28, 1997 HAS BEEN PERFORMED.** NOTE: ALL FRONT KNUCKLE/BEARING/HUB REPAIR PROCEDURES FOR STEPS 1 THROUGH 5, CAN BE FOUND IN THE 1998 NEON SERVICE MANUAL (PUBLICATION NUMBER 81-270-8025) GROUP 2 (SUSPENSION). 1. Remove both left and right front knuckle/bearing/hub assemblies. 2. Press the hub out of the old knuckle/bearing/hub assemblies. 3. Press the old hubs into the new knuckle/bearing assemblies. **4. Before the knuckle/bearing/hub assemblies are installed on the vehicle, put a small amount of grease (Wheel Bearing Lube - p/n 04318064) on the entire face of the driveshaft that makes contact with the hub bearing assembly (Figure 1).** 5. Install both left and right front knuckle/bearing/hub assemblies. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Customer Interest for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension Popping/Creaking Noises > Page 5114 **6. Replace the upper strut mount by following the procedures in the 1998 Neon Service Manual (Publication No. 81-270-8025), Removal/Installation, pages 2-16 to 2-17, and Assembly/Disassembly procedures 1 thru 5 on pages 2-30 to 2-31 (Figure 2). The torque for the new upper strut mount nuts is 61 Nm (45 ft.lbs).** **7. Remove and replace the right engine mount as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) (SOHC - pg 9-18)(DOHC - pg 9-64). After replacing the right engine mount, squirt enough grease (Silicone Spray - p/n 04318070) between the mount snubber and the engine bracket to fill the gap (Figure 3).** NOTE: IF THE SILICONE SPRAY (P/N 04318070) IS NOT AVAILABLE, ANOTHER SILICONE SPRAY MAY BE USED. HOWEVER THE SUBSTITUTE SILICONE SPRAY MUST NOT BE PETROLEUM BASED. **8. Inspect and tighten remaining suspension components to specification; repair or replace as needed.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-05-30-93 Knuckles and Mounts - Replace - All 2.9 Hrs. 02-05-39-91 Upper Strut Mounts and Engine Mount - Replace 1.3 Hrs. 09-40-21-91 Engine Mount Replace 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension - Popping/Creaking Noises Front Steering Knuckle: All Technical Service Bulletins Front Suspension - Popping/Creaking Noises NO: 02-02-97 Rev. A GROUP: Front Suspension EFFECTIVE DATE: Dec. 15, 1997 SUBJECT: Popping/Creaking Noise in Front Suspension THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-02-97 DATED FEBRUARY 28, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL FRONT SUSPENSION NOISE DIAGNOSTICS/REPAIRS HAVE BEEN ADDED. THE ADDITIONS ARE HIGHLIGHTED WITH ASTERISKS. MODELS: 1995 - 1998 (PL) Neon SYMPTOM/CONDITION: **A popping noise from the front suspension may be experienced while: ^ Going in reverse or forward with the steering wheel turned completely in one direction (parking lot maneuvers). ^ Shifting from drive to reverse, reverse to drive, etc. ^ Pulling in/out of driveway. ^ Large dips/bumps in the road such as speed bumps. ** DIAGNOSIS: If the customer describes the front suspension noise in conditions such as those described above, perform the Repair Procedure. PARTS REQUIRED: NOTE: THE 1995 NEONS BUILT IN 1994 USED 13" KNUCKLE ASSEMBLIES WITH 13" OR 14" WHEELS. LATER BUILT VEHICLES HAVE 13" OR 14" KNUCKLE ASSEMBLIES TO MATCH ORIGINAL WHEEL SIZE. TO DETERMINE THE PROPER KNUCKLE SIZE, COUNT THE STUDS ON THE HUB THEN REFER TO THE PARTS LIST PROVIDED IN THIS BULLETIN. CAUTION: DO NOT USE THE WHEEL SIZE TO DETERMINE PROPER KNUCKLE PART NUMBERS. REPAIR PROCEDURE: **This bulletin involves inspecting/replacing as needed both front wheel bearings and steering knuckles, front upper strut mounts, engine mounts, and lubing the driveshafts.** Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension - Popping/Creaking Noises > Page 5120 **NOTE: USE TABLE TO DETERMINE WHICH STEPS TO PERFORM BASED ON VEHICLE BUILD DATE AND IF TECHNICAL SERVICE BULLETIN 02-02-97, DATED FEBRUARY 28, 1997 HAS BEEN PERFORMED.** NOTE: ALL FRONT KNUCKLE/BEARING/HUB REPAIR PROCEDURES FOR STEPS 1 THROUGH 5, CAN BE FOUND IN THE 1998 NEON SERVICE MANUAL (PUBLICATION NUMBER 81-270-8025) GROUP 2 (SUSPENSION). 1. Remove both left and right front knuckle/bearing/hub assemblies. 2. Press the hub out of the old knuckle/bearing/hub assemblies. 3. Press the old hubs into the new knuckle/bearing assemblies. **4. Before the knuckle/bearing/hub assemblies are installed on the vehicle, put a small amount of grease (Wheel Bearing Lube - p/n 04318064) on the entire face of the driveshaft that makes contact with the hub bearing assembly (Figure 1).** 5. Install both left and right front knuckle/bearing/hub assemblies. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension - Popping/Creaking Noises > Page 5121 **6. Replace the upper strut mount by following the procedures in the 1998 Neon Service Manual (Publication No. 81-270-8025), Removal/Installation, pages 2-16 to 2-17, and Assembly/Disassembly procedures 1 thru 5 on pages 2-30 to 2-31 (Figure 2). The torque for the new upper strut mount nuts is 61 Nm (45 ft.lbs).** **7. Remove and replace the right engine mount as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) (SOHC - pg 9-18)(DOHC - pg 9-64). After replacing the right engine mount, squirt enough grease (Silicone Spray - p/n 04318070) between the mount snubber and the engine bracket to fill the gap (Figure 3).** NOTE: IF THE SILICONE SPRAY (P/N 04318070) IS NOT AVAILABLE, ANOTHER SILICONE SPRAY MAY BE USED. HOWEVER THE SUBSTITUTE SILICONE SPRAY MUST NOT BE PETROLEUM BASED. **8. Inspect and tighten remaining suspension components to specification; repair or replace as needed.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-05-30-93 Knuckles and Mounts - Replace - All 2.9 Hrs. 02-05-39-91 Upper Strut Mounts and Engine Mount - Replace 1.3 Hrs. 09-40-21-91 Engine Mount Replace 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 5122 Front Steering Knuckle: Description and Operation The steering knuckle is a single casting with legs machined for attachment to the front strut assembly and lower control arm ball joint. The steering knuckle also has machined abutments on the casting to support and align the front brake caliper assembly. The knuckle also holds the front drive shaft outer C/V joint hub and bearing assembly. The hub is positioned through the bearing and knuckle, with the constant velocity stub shaft splined through the hub. The outer C/V joint is retained to the hub/ bearing using a hub nut. The hub nut is held on the stub shaft using a nut retainer and cotter pin. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 5123 Front Steering Knuckle: Testing and Inspection The front suspension steering knuckle is not a repairable component of the front suspension. IT MUST BE REPLACED IF FOUND TO BE DAMAGED IN ANY WAY. If it is determined that the steering knuckle is bent when servicing the vehicle, no attempt is to be made to straighten the steering knuckle. NOTE: On this vehicle the steering knuckle must be removed from the vehicle when servicing the front hub bearing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal Front Steering Knuckle: Service and Repair Removal 1. Remove cotter pin, nut lock, and spring washer. CAUTION: Wheel bearing damage will result if after loosening hub nut, vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires. 2. Loosen hub nut while vehicle is on the floor with the brakes applied. The hub and driveshaft are splined together through the knuckle (bearing) and retained by the hub nut. 3. Raise vehicle on jack stands or centered on a frame contact type hoist. 4. Remove wheel lug nuts, and front tire and wheel assembly from the hub. 5. Remove front disc brake caliper to steering knuckle attaching bolts. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5126 6. Remove disc brake caliper assembly from steering knuckle. Caliper is removed by first lifting bottom of caliper away from steering knuckle, and then removing top of caliper out from under steering knuckle. 7. Support brake disc brake caliper assembly using a wire hook and not by hydraulic hose. 8. Remove the braking disc from the front hub/ bearing assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5127 9. Remove the nut attaching outer tie rod end to the steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with wrench. 10. Remove the tie rod end stud from steering knuckle arm, using Remover, Special Tool MB-990635, or equivalent. 11. Remove nut and bolt, clamping ball joint stud, from steering knuckle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5128 12. Separate ball joint stud from steering knuckle by prying down on lower control arm. NOTE: Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get cut. - Care must be taken not to separate the inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint, driveshaft must be supported. 13. Pull steering knuckle assembly out and away from outer C/V joint of the driveshaft assembly. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during removal. Remove nuts while holding bolts stationary in the steering knuckles. 14. Remove the 2 steering knuckle to strut damper clevis bracket attaching bolts. 15. The cartridge type front wheel bearing used on this vehicle is not transferable to the replacement steering knuckle. If the replacement steering knuckle does not come with a hub and bearing assembly, a new bearing must be installed in the steering knuckle. Installation of the new wheel bearing must be done before installing steering knuckle on vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5129 Front Steering Knuckle: Service and Repair Installation 1. Install a new cartridge hub and bearing assembly into the steering knuckle. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in the steering knuckles. 2. Install steering knuckle back in clevis bracket of strut damper assembly. Install the strut damper to steering knuckle attaching bolts. Note: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned in steering knuckle during installation. Torque attaching nuts to 54 Nm (40 ft. lbs.) plus an additional 1/4 turn after specified torque is met. 3. Slide drive shaft back into front hub and bearing assembly. Then install steering knuckle onto the ball joint stud. 4. Install a NEW steering knuckle to ball joint stud, clamp bolt and nut. Torque the clamp bolt to 100 Nm (75 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5130 5. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket, torque tie rod end attaching nut to 55 Nm (40 ft. lbs.). 6. Install braking disc back on hub and bearing assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5131 7. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding top of caliper under top abutment on steering knuckle. Then installing bottom of caliper against bottom abutment of steering knuckle. 8. Install caliper assembly to steering knuckle attaching bolts. Torque caliper assembly attaching bolts to 31 Nm (23 ft. lbs.). 9. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install hub nut onto threads of stub axle and tighten nut. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5132 10. With vehicle brakes applied to keep braking disc from turning, tighten hub nut to a torque of 183 Nm (135 ft. lbs.). 11. Install front wheel and tire assembly. Install front wheel lug nuts and torque to 135 Nm (100 ft. lbs.). 12. Lower vehicle. 13. Install the spring washer, hub nut lock, and new cotter pin. Wrap cotter pin prongs tightly around the hub nut lock. 14. Set front Toe on vehicle to required specification. Refer to Alignment. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications Lateral Stabilizer Rod: Specifications Attaching Nut ....................................................................................................................................... .................................................... 95 Nm (70 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 5136 Lateral Stabilizer Rod: Testing and Inspection Inspect the lateral link isolator bushings and sleeves for signs of damage or deterioration. If the lateral link isolator bushings or sleeves are damaged or are deteriorated, replacement of the lateral link assembly will be required. The isolator bushings are not serviceable as a separate component of the lateral link assembly. Inspect the lateral links for signs of contact with the ground or road debris which has bent or caused other damage to the lateral link assembly. If the lateral link is bent or damaged, the lateral link will require replacement. Do not attempt to repair or straighten a lateral link. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 5137 Lateral Stabilizer Rod: Service and Repair GENERAL INFORMATION The rear suspension lateral links are only serviced as complete assemblies. The isolator bushings used in the lateral links are not serviced as separate components. The rear lateral link assemblies are unique, having different size bushings to accommodate the rear Toe adjustment cams. The rearward lateral links, must be installed with small bushing sleeve at knuckle and large bushing sleeve at rear crossmember. This is required to accommodate the rear Toe adjustment cam. REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the rear wheel and tire assembly from the side of the vehicle requiring lateral link removal. 3. Remove the nut, bolt and washers attaching the lateral links to the knuckle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 5138 4. Remove nut, bolt, washer and Toe adjustment cam, attaching lateral links requiring removal, from rear crossmember. Then remove lateral links from vehicle. INSTALL Rear lateral links when being installed, must be specifically positioned and orientated on the vehicle. The lateral link having same size bushing sleeves, must be mounted to the crossmember and knuckle toward front of vehicle. The lateral link with different size bushing sleeves, must be mounted to the crossmember and knuckle toward rear of vehicle. The lateral link with small and large bushing sleeves, must be installed with small bushing sleeve at knuckle and large bushing sleeve at rear crossmember. This is required to accommodate the rear Toe adjustment cam at rear crossmember. The lateral link mounting bolts are different lengths, and need to be installed in specific locations and direction on vehicle. The lateral link mounting bolt at knuckle MUST be installed, with head of bolt facing front of vehicle. The lateral link mounting bolt at crossmember MUST be installed, with head of bolt facing rear of vehicle. The long attaching bolt must be used at rear crossmember and short bolt used at knuckle. 1. Install washer on short lateral link attaching bolt. Then install short lateral link attaching bolt, into lateral link having the same size bushing sleeves. Then install lateral link, bolt and washer onto knuckle as an assembly, with head of bolt facing to front of vehicle. 2. Install lateral link with small and large bushing sleeve, on lateral link attaching bolt in rear knuckle. Small bushing sleeve must be installed on bolt in rear knuckle with large bushing sleeve at crossmember of vehicle. 3. Install washer and nut onto lateral link attaching bolt at rear knuckle. Do not tighten the lateral link to rear knuckle attaching bolt at this time. 4. Install Toe adjustment cam on long lateral link attaching bolt. Install long lateral link attaching bolt and adjustment cam, into lateral link toward rear of vehicle, having the large bushing sleeve. Then pass lateral link attaching bolt into rear crossmember. Head of long lateral link to crossmember attaching bolt must face to rear of vehicle when installed. 5. Position forward rear lateral link against rear crossmember. Then pass the lateral link attaching bolt through front lateral link bushing sleeve. 6. Install washer and nut onto lateral link attaching bolt at rear crossmember. Do not tighten the lateral link to rear crossmember attaching bolt at this time. 7. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 8. Lower vehicle to the ground. 9. With suspension supporting total weight of vehicle, and lateral links at correct curb height, torque both lateral link attaching bolts to 95 Nm (70 ft. lbs.). 10. Check and reset rear wheel TOE to specifications if required. Refer to Front And Rear Toe Setting Procedure in Wheel Alignment. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Description and Operation Rear Knuckle: Description and Operation A forged rear knuckle bolts to each rear strut assembly. The movement of the rear knuckle is controlled laterally using two lateral arms attached to the knuckle. The outboard ends of the two lateral arms are mounted forward and rearward of the spindle centerline, and inboard ends are mounted to the rear crossmember. Fore and aft movement of the knuckle is controlled by using a tension strut. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Description and Operation > Page 5142 Rear Knuckle: Testing and Inspection The rear suspension knuckle is not a repairable component of the rear suspension. If it is determined that the knuckle is broken or bent when servicing the vehicle, no attempt is to be made to repair or to straighten the knuckle. THE KNUCKLE MUST BE REPLACED IF FOUND TO BE DAMAGED IN ANY WAY. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Removal Rear Knuckle: Service and Repair Removal 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the rear wheel and tire assembly from the vehicle. 3. If vehicle is equipped with rear disc brakes, remove the rear caliper assembly from the adapter. Refer to Brakes and Traction Control. After removing caliper assembly store caliper by hanging it from frame of vehicle. Do not let weight of rear caliper assembly hang from flexible brake hose. 4. If vehicle is equipped with rear disc brakes, remove rear braking disc from hub. If vehicle is equipped with rear drum brakes, remove brake drum from hub. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Removal > Page 5145 5. If vehicle is equipped with ABS brakes, remove the speed sensor head from the rear brake support plate or disc brake adapter. 6. Remove rear hub and bearing assembly retaining nut. Then remove the hub and bearing assembly from knuckle. 7. If vehicle is equipped with rear drum brakes remove the 4 bolts attaching rear brake support plate to knuckle. Then remove brake support plate, brake shoes and wheel cylinder as an assembly from rear knuckle. It is not necessary to remove brake flex hose from wheel cylinder when removing support plate. Brake support plate when removed, must be supported in same manner as caliper assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Removal > Page 5146 8. On vehicles equipped with rear disc brakes, remove the 4 bolts attaching disc brake adapter to rear knuckle. Then remove the adapter, rotor shield, park brake shoes and park brake cable as an assembly from knuckle. CAUTION: The knuckle to strut assembly attaching bolts are serrated and must not be turned during removal. Loosen and remove nuts while holding bolts stationary in knuckle. 9. Loosen but do not remove at this time, the 2 strut assembly to knuckle attaching bolts. Then remove the lateral links to knuckle attaching bolt. 10. Hold tension strut from turning by using a large adjustable wrench on flat of tension strut and remove tension strut nut. Then remove nut, tension strut retainer and rear tension strut bushing from tension strut at rear knuckle. 11. Remove both rear knuckle to strut assembly clevis bracket attaching bolts. If vehicle is equipped with a rear sway bar also remove the sway bar link to strut mounting bracket. 12. Remove knuckle assembly from strut, by sliding knuckle straight out of clevis bracket on strut assembly. Then remove knuckle from tension strut. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Removal > Page 5147 Rear Knuckle: Service and Repair Installation 1. Insert tension strut, tension strut bushing and tension strut retainer into knuckle. Then install knuckle into clevis bracket on rear strut assembly. Be sure stepped area of bushing is squarely seated into hole in knuckle. CAUTION: The knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Tighten and torque nuts while holding bolts stationary in knuckle. 2. Install the 2 strut assembly clevis bracket to knuckle attaching bolts and nuts. Torque the attaching bolts to 95 Nm (70 ft. lbs.). 3. Install the lateral arms to knuckle attaching bolt, washers and nut as shown. Do not tighten the lateral link bolt at this time. The vehicle must be at curb height when tightening the lateral link bolts. 4. Install tension strut bushing, tension strut retainer and nut on tension strut. When installing tension strut retainers, the retainers must be installed on tension strut, with cupped side of retainer facing away from bushing and knuckle. 5. Position a large adjustable wrench on flat of tension strut to keep it from turning, and then torque tension strut nut to 95 Nm (70 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Removal > Page 5148 6. On vehicles equipped with rear drum brakes, install rear brake support plate assembly onto the knuckle. Install the 4 bolts attaching rear brake support plate to rear knuckle. Torque attaching bolts to 68 Nm (50 ft. lbs.). 7. On vehicles equipped with rear disc brakes, install the disc brake adapter on knuckle Install the 4 bolts attaching the disc brake adapter to knuckle. Torque attaching bolts to 68 Nm (50 ft. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Removal > Page 5149 8. If vehicle is equipped with ABS brakes, install speed sensor head into rear brake support plate or disc brake adapter. Torque speed sensor head mounting bolt to 7 Nm (60 inch lbs.). CAUTION: The hub/bearing retaining nut must be tightened to but must not exceed its required torque specification. The proper torque specification of the retaining nut is critical to the life of the hub bearing. 9. Install rear hub and bearing assembly on knuckle. Install hub and bearing assembly retaining nut, and torque to 217 Nm (160 ft. lbs). 10. If vehicle is equipped with rear disc brakes, install rear braking disc on hub. If vehicle is equipped with rear drum brakes, install the brake drum on hub. 11. If vehicle is equipped with rear disc brakes, install rear braking disc on hub. Carefully install rear brake caliper over braking disc and install on adapter. Tighten the caliper assembly to adapter mounting bolts to 22 Nm (192 inch lbs.). Refer to Brakes and Traction Control. 12. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 13. Lower vehicle. 14. With suspension supporting total weight of vehicle, and lateral links at correct curb height, torque both lateral link attaching bolts to 95 Nm (70 ft. lbs.). 15. Check and reset rear wheel TOE to specifications if required. Refer to Front And Rear Toe Setting Procedure in Wheel Alignment. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Specifications Stabilizer Bushing: Specifications FRONT: Retainer Bolts ...................................................................................................................................... ................................................. 28 Nm (21 ft. lbs.) REAR: Retainer Bolts ...................................................................................................................................... ............................................ 34 Nm (300 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Specifications > Page 5154 Stabilizer Bushing: Testing and Inspection Inspect for broken or distorted sway bar bushings, bushing retainers, and worn or damaged sway bar to strut attaching links. If sway bar to front suspension cradle bushing replacement is required, bushing can be removed from sway bar by opening slit and peeling bushing off sway bar. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Specifications > Page 5155 Stabilizer Bushing: Service and Repair If stabilizer bar to frame rail bushings require replacement at time of inspection, install new bushings before installing stabilizer bar. Bushings are replaced by opening slit on bushings and peeling them off stabilizer bar. Install new bushings on stabilizer bar, by spreading bushing at slit and forcing them on stabilizer bar. Bushings must be installed on stabilizer bar with slit in bushing facing rear of vehicle when stabilizer bar is installed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications Stabilizer Link: Specifications FRONT: Attaching Nuts ..................................................................................................................................... ................................................. 28 Nm (21 ft. lbs.) REAR: Attaching Nuts ..................................................................................................................................... ............................................ 34 Nm (300 inch lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications > Page 5159 Stabilizer Link: Testing and Inspection Inspect the bushings and sleeves in the stabilizer bar attaching links for damage or deterioration. Inspect the stabilizer bar attaching link to ensure it is not bent or broken. If any of these conditions are present when inspecting the attaching links, replacement of the attaching link is required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-06-98A > Jun > 98 > Front Suspension - Popping Noise On Bumps Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Front Suspension - Popping Noise On Bumps NO.: 02-06-95 Rev. A GROUP: Suspension DATE: Jun. 19, 1998 THIS BULLETIN SUPERCEDES TECHNICAL SERVICE BULLETINS 02-01-98 DATED MARCH 27, 1998 AND 02-06-98 DATED JUNE 5, 1998. BOTH BULLETINS SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE SYMPTOM/CONDITION AND THE DIAGNOSTIC PROCEDURE HAVE BEEN REVISED. MODELS: 1995 - 1998 (PL) Neon SYMPTOM/CONDITION: **A popping noise from the front end while traveling over bumps with wheels straight or when turning. ** The popping noise may be more apparent when suspension is wet, such as in a heavy rain. DIAGNOSIS: **Wet the front coil springs and surrounding suspension components with a light spray from a garden hose. Immediately drive the vehicle over a small bump (such as a speed bump) while making a turn. If a popping noise is heard, perform the Repair Procedure. ** PARTS REQUIRED: 2 05273399 Spring Sleeve, Front Coil Springs REPAIR PROCEDURE: This bulletin involves the addition of a spring sleeve to each front coil spring. 1. Remove the strut assembly as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) on page 2-15. 2. Disassemble the strut assembly as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) on page 2-30. 3. Clean the mating surface of the spring and strut spring seat. If surface rust is present, use a smooth scuff pad to remove the rust. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-06-98A > Jun > 98 > Front Suspension - Popping Noise On Bumps > Page 5168 NOTE: THE EFFECTED AREA WILL SHOW SIGNS OF RUST OR PAINT WEAR. THIS IS THE AREA THAT SHOULD BE COVERED BY THE SPRING SLEEVE. 4. Apply the spring sleeve (p/n 5273399) to the spring. The spring sleeve should be positioned onto the spring to cover the effected area (Figure 1). 5. Assemble the strut assembly following the procedure in the 1995 Neon Service Manual (Publication No. 81-270-8025) beginning on page 2-32. 6. Install the strut assembly into the vehicle following the procedure in the 1998 Neon Service Manual (Publication No. 81-270-8025) beginning on page 2-16. 7. Repeat the procedure for the other side. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-27-01-92 1.0 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-06-98A > Jun > 98 > Front Suspension - Popping Noise On Bumps Suspension Spring ( Coil / Leaf ): Customer Interest Front Suspension - Popping Noise On Bumps NO.: 02-06-95 Rev. A GROUP: Suspension DATE: Jun. 19, 1998 THIS BULLETIN SUPERCEDES TECHNICAL SERVICE BULLETINS 02-01-98 DATED MARCH 27, 1998 AND 02-06-98 DATED JUNE 5, 1998. BOTH BULLETINS SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE SYMPTOM/CONDITION AND THE DIAGNOSTIC PROCEDURE HAVE BEEN REVISED. MODELS: 1995 - 1998 (PL) Neon SYMPTOM/CONDITION: **A popping noise from the front end while traveling over bumps with wheels straight or when turning. ** The popping noise may be more apparent when suspension is wet, such as in a heavy rain. DIAGNOSIS: **Wet the front coil springs and surrounding suspension components with a light spray from a garden hose. Immediately drive the vehicle over a small bump (such as a speed bump) while making a turn. If a popping noise is heard, perform the Repair Procedure. ** PARTS REQUIRED: 2 05273399 Spring Sleeve, Front Coil Springs REPAIR PROCEDURE: This bulletin involves the addition of a spring sleeve to each front coil spring. 1. Remove the strut assembly as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) on page 2-15. 2. Disassemble the strut assembly as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) on page 2-30. 3. Clean the mating surface of the spring and strut spring seat. If surface rust is present, use a smooth scuff pad to remove the rust. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-06-98A > Jun > 98 > Front Suspension - Popping Noise On Bumps > Page 5174 NOTE: THE EFFECTED AREA WILL SHOW SIGNS OF RUST OR PAINT WEAR. THIS IS THE AREA THAT SHOULD BE COVERED BY THE SPRING SLEEVE. 4. Apply the spring sleeve (p/n 5273399) to the spring. The spring sleeve should be positioned onto the spring to cover the effected area (Figure 1). 5. Assemble the strut assembly following the procedure in the 1995 Neon Service Manual (Publication No. 81-270-8025) beginning on page 2-32. 6. Install the strut assembly into the vehicle following the procedure in the 1998 Neon Service Manual (Publication No. 81-270-8025) beginning on page 2-16. 7. Repeat the procedure for the other side. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-27-01-92 1.0 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Front Suspension Spring ( Coil / Leaf ): Description and Operation Front Coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. During service procedures when both springs are removed, mark springs to ensure installation in original position. Each coil spring comes with a plastic sleeve on the second coil of the spring. This plastic sleeve is a noise insulator for the coil spring. If coil springs require replacement, be sure that the springs needing replacement, are replaced with springs meeting the correct load rating for the vehicle and its specific options. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Front > Page 5177 Suspension Spring ( Coil / Leaf ): Description and Operation Rear Rear coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. During service procedures when both rear coil springs are removed, mark the coil springs to ensure installation of the springs in their original position. If coil springs require replacement, be sure the springs needing replacement, are replaced with springs meeting the correct load rating for the vehicle and its specific options. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Page 5178 Suspension Spring ( Coil / Leaf ): Service and Repair Coil springs are rated separately for each side of vehicle depending on optional equipment and type of service. During service procedures where both springs are removed, mark springs (Chalk, Tape, etc.) to ensure installation in original position. If the coils springs require replacement. Be sure that the springs needing replacement, are replaced with springs meeting the correct load and spring rate for the vehicle. NOTE: During service procedures requiring removal or installation of a coil spring with Spring Compressor, Special Tool C-4838, or equivalent. It is required that the first full top and bottom coil of the coil spring be captured by the jaws of spring compressor. Replacement of the coil spring requires removal of the strut assembly from the vehicle, and the disassembly of the strut. Refer to strut for the required removal and replacement procedure for the strut assembly. Then refer to strut for the required procedure to disassemble and assemble the strut assembly for the removal of the coil spring. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Alignment & Suspension - Specifications & Adjustment Suspension Strut / Shock Absorber: Technical Service Bulletins Alignment & Suspension Specifications & Adjustment NO: 02-04-97 GROUP: Suspension DATE: May 16, 1997 SUBJECT: Front End Alignment Torque Specifications & Shock Adjustment Procedures On Competition Package MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH THE COMPETITION PACKAGE SALES CODE (ACR) SUSPENSION SALES CODE (SDK). DISCUSSION: The alignment on ACR equipped vehicles must be set to the preferred specifications provided in the 1997 Neon Service Manual (Publication Number 81-270-7025) page 2-7. After each final setting the nuts should then be torqued to 75 ft.lbs plus an additional 90 degree turn. It is important that the proper torque be used to maintain the proper alignment. If the alignment is outside of specifications, rapid and excessive tire wear will result. Starting in 1997, Neon competition package (ACR) vehicles come equipped with adjustable strut dampers on all four wheels. The struts are finely tuned to the ride and handling profile of the entire suspension system. If the customer wishes to change the dampening force for special conditions the dampening characteristics of the strut dampers are adjustable on the ACR equipped vehicles. The knob for adjusting the strut can be found in a packet located in the glove compartment. The adjustment procedures are as follows: 1. The top end of the adjusting rod has flats over which the adjusting knob will fit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Alignment & Suspension - Specifications & Adjustment > Page 5183 2. Install the knob over the top end of the front or rear damper and lock it into position by turning counterclockwise slowly until the knob engages, (Illustration). 3. Turn the adjusting knob clockwise, if resistance is felt do not use force, as the damper is in an unadjusted position. Reverse the adjustment slightly and try again. When the damper is in the full clockwise position, this is the minimum (City Ride) position. 4. To adjust the dampening force, the adjusting knobs has to be turned in the direction of the arrow for increased dampening and the opposite direction for decreased dampening. NOTE: BOTH THE LEFT AND RIGHT STRUT DAMPERS MUST BE ADJUSTED IDENTICALLY. FAILURE TO DO SO COULD PRODUCE UNSTABLE HANDLING AND UNEVEN TIRE TREAD WEAR. 5. The following is a description of the various settings and the adjustment procedure. A. City Ride - To enjoy the most comfortable city ride, the struts should be left in the "minimum" position as they are set from the assembly plant. To set to minimum the knob should be turned completely clockwise. B. Cross Country - The cross country setting will give the car a firmer handling characteristic, but yet will still be very comfortable to drive. To set, turn the adjusting knob 1/2 turn counter clockwise from the "minimum" position. C. G.T./Aggressive Driving - This setting equates the car's handling to a cross-country grand turismo car, offering increased cornering ability, improved road feel and precise directional stability at higher speeds. To set turn the adjusting knob 1 turn counter clockwise from the "minimum" position. 6. Remove the adjusting knob before closing the hood or trunk. The vehicle should not be driven with the adjusting knob in place. NOTE: DURING INSPECTION/SERVICING A THIN FILM OF OIL AND DUST COLLECTION MAY BE NOTICED ON THE OUTSIDE OF THE STRUT TUBE. THIS IS A NORMAL CONDITION WHICH OCCURS DURING THE DAMPER INTERNAL SEAL "BREAK-IN" PERIOD AND DOES NOT AFFECT THE PERFORMANCE OF THE STRUT AND DOES NOT INDICATE THE NEED FOR STRUT REPLACEMENT. STRUT REPLACEMENT SHOULD ONLY OCCUR IF THE STRUT LEAKAGE IS SUFFICIENT TO COVER THE ENTIRE STRUT DAMPER TUBE AND HAS "DRIPPED" ONTO THE LOWER CONTROL ARM OR ONTO THE PAVEMENT DURING OVERNIGHT PARKING. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Page 5184 Suspension Strut / Shock Absorber: Specifications FRONT: Attaching Nuts ..................................................................................................................................... ............................................ 34 Nm (300 inch lbs.) Clevis Bracket To Steering Knuckle ............................................................................................................................................ 54 Nm (40 ft. lbs.) +90° Shaft Nut ......................................................................................................................... ...................................................................... 74 Nm (55 ft. lbs.) REAR: Attaching Nuts ..................................................................................................................................... ............................................ 34 Nm (300 inch lbs.) Clevis Bracket To Knuckle Nut/Bolt .................................................................................................................................................... 95 Nm (70 ft. lbs.) Shaft Nut ..................................................................................................................... .......................................................................... 75 Nm (55 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front Suspension Strut / Shock Absorber: Description and Operation Front The front strut and suspension of the vehicle is supported by coil springs positioned around the struts. The springs are contained between an upper seat, located just below the top strut mount assembly and a lower spring seat on the strut lower housing. The top of each strut assembly is bolted to the upper fender reinforcement (shock tower) through a rubber isolated mount. The bottom of the strut assembly attaches to the top of the steering knuckle using 2 thru-bolts and prevailing torque nuts. Caster and camber is a fixed setting (net build) on all vehicles and is not required to be adjusted. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front > Page 5187 Suspension Strut / Shock Absorber: Description and Operation Rear The rear strut assemblies support the weight of the vehicle using coil springs positioned around the struts. The coil springs are contained between the upper mount of the strut assembly and a lower spring seat on the body of the strut assembly. The top of each strut assembly is bolted to the top of the inner fender through a rubber isolated mount. The bottom of the strut assembly attaches to the rear knuckle using 2 thru-bolts and prevailing torque nuts. Rear Caster and camber on this vehicle is a fixed setting (net build) and is not required to be adjusted as a normal procedure when performing an alignment on this vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension Strut / Shock Absorber: Testing and Inspection Front 1. Inspect for damaged or broken coil springs. 2. Inspect for torn or damaged strut assembly dust boots. 3. Lift dust boot and inspect strut assembly for evidence of fluid running from the upper end of fluid reservoir. (Actual leakage will be a stream of fluid running down the side and dripping off lower end of unit). A slight amount of seepage between the strut rod and strut shaft seal is not unusual and does not affect performance of the strut assembly. Also inspect jounce bumpers for signs of damage or deterioration. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front > Page 5190 Suspension Strut / Shock Absorber: Testing and Inspection Rear 1. Inspect for damaged or broken coil springs. 2. Inspect for torn or damaged Strut assembly dust boots. 3. Inspect for damaged lower spring isolator. 4. Lift dust boot and inspect strut assembly for evidence of fluid running from the upper end of fluid reservoir. (Actual leakage will be a stream of fluid running down the side and dripping off lower end of unit). A slight amount of seepage between the strut rod and strut shaft seal is not unusual and does not affect performance of the strut assembly. Also inspect jounce bumpers for signs of damage or deterioration. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement Suspension Strut / Shock Absorber: Service and Repair Replacement Front WARNING: Do not remove strut rod nut while strut assembly is installed in vehicle, or before strut assembly spring is compressed. REMOVE 1. Loosen wheel nuts. 2. Raise vehicle on jack stands or centered on a frame contact type hoist. 3. Remove wheel and tire assembly from location on front of' vehicle requiring Strut removal. 4. If both strut assemblies arc removed, mark the Strut assemblies right or left according to which side of' the vehicle they were removed from. 5. Remove hydraulic brake hose routing bracket and attaching screw from strut damper bracket. If vehicle is equipped with Anti-Lock brakes, hydraulic hose routing bracket is combined with speed sensor cable routing bracket. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during removal. Remove nuts while holding bolts stationary in the steering knuckles. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement > Page 5193 6. Remove the 2 strut assembly clevis bracket to steering knuckle attaching bolts. 7. Remove the 3 nuts attaching the strut assembly upper mount to the strut tower of the vehicle. INSTALL 1. Install strut assembly into strut tower, aligning the 3 studs on the upper strut mount into the holes in shock tower. Ins tall the 3 upper strut mount retaining nut and washer assemblies. Torque the 3 nuts to 31 Nm (23 ft. lbs.). CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in the steering knuckles. 2. Align strut assembly with steering knuckle. Position arm of steering knuckle into strut assembly, aligning the strut assembly to steering knuckle mounting holes. Install the 2 strut assembly to steering knuckle attaching bolts. Attaching bolts should be installed with the nuts facing the front of the vehicle. Torque both attaching bolts to 53 Nm (40 ft. lbs.) plus an additional 1/4 turn after specified torque is met. 3. Install hydraulic brake hose routing bracket and attaching screw onto strut damper bracket. If vehicle is equipped with Anti-Lock brakes, hydraulic hose routing bracket is combined with speed sensor cable routing bracket. Torque bracket attaching bolts to 13 Nm (10 ft. lbs.). 4. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). Rear REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the rear wheel and tire assembly from the vehicle. 3. Remove hydraulic flex hose bracket, from bracket on rear strut assembly. If vehicle is equipped with Anti-Lock brakes, the wheel speed sensor cable routing clip is also attached to the strut assembly bracket. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement > Page 5194 4. Support rear knuckle, suspension and brake components of' vehicle before removing clevis bracket to knuckle attaching bolts. Do not let weight of rear knuckle and assembled components hang unsupported when strut is removed. CAUTION: The knuckle to strut assembly attaching bolts are serrated and must not be turned during removal. Remove nuts while holding bolts stationary in knuckle. 5. Remove the 2 clevis bracket bolts attaching strut assembly to rear knuckle. 6. Lower vehicle. Access to rear upper strut mount to strut tower attaching bolts, is through the trunk of the vehicle. 7. Remove carpet (if required) from top of strut tower. Then remove rubber dust shield from top of strut tower, this will allow easier access to upper strut mount attaching nuts. 8. Loosen but do not remove the 4 upper strut mount to strut tower attaching nuts. Then while supporting the strut assembly fully remove the 4 strut mount attaching nuts. 9. Remove strut assembly from knuckle, by sliding knuckle out of clevis bracket on strut assembly. Then remove strut assembly from vehicle. INSTALL 1. Position strut assembly back into vehicle with the 4 studs on strut mount assembly through holes in strut tower of vehicle. Install the 4 strut mount Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement > Page 5195 to body attaching nuts onto mount studs. Torque the 4 strut mount to body attaching nuts to 34 Nm (300 inch lbs). 2. Install dust shield into hole on top of strut tower. Install carpeting back on top of rear strut tower. 3. Raise vehicle. CAUTION: The knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install and torque nuts while holding bolts stationary in knuckle. 4. Install knuckle assembly into clevis bracket on strut assembly. Install the 2 clevis bracket to knuckle assembly attaching bolts and nuts. Torque both clevis bracket to knuckle assembly attaching nuts to 95 Nm (70 ft. lbs.). 5. Install hydraulic flex hose bracket, on strut assembly bracket. Install and securely tighten bolt attaching hose bracket to strut bracket. If vehicle is equipped with Anti-Lock brakes, the wheel speed sensor cable routing clip is also attached to the strut assembly bracket. 6. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat tightening sequence to full specified torque of 135 Nm (100 ft. lbs.). 7. Lower vehicle to the ground. 8. Check and reset rear wheel TOE to specifications if required. Refer to Alignment. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement > Page 5196 Suspension Strut / Shock Absorber: Service and Repair Overhaul Front DISASSEMBLE 1. Clamp the strut assembly in a vise, with the strut in a vertical position. When clamping the strut assembly in the vise, do not clamp strut using the body of the strut only by strut clevis bracket. 2. Mark coil spring and strut assembly right or left, according to which side of the vehicle the strut was removed from, and which strut coil spring was removed from. WARNING: Do not remove strut rod nut, before strut assembly coil spring is compressed, removing spring tension from upper spring seat and bearing assembly. - When compressing coil spring for removal from strut assembly, the first full top and bottom coil of the coil spring must be captured by the jaws of the coil spring compressor. 3. Compress the strut assembly coil spring, using Spring Compressor, Special Tool C-4838, or equivalent. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement > Page 5197 4. Install Socket, Strut Nut, Special Tool L-4558A (or L-4558), or equivalents on the strut shaft retaining nut. Then install a 10 mm socket on the hex of the strut damper shaft. While holding strut shaft from turning, remove the strut shaft retaining nut. 5. Remove the strut assembly mount/isolator from the strut. 6. Remove the upper spring seat, pivot bearing and dust shield as an assembly from the strut. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement > Page 5198 7. Remove the jounce bumper from the shaft of the strut assembly. 8. Remove the coil spring from the strut assembly. Mark left and right on the coil springs for their installation back on the correct side of the vehicle. WARNING: If a replacement coil spring is to be installed on the strut assembly, the first full top and bottom coil of the spring must be captured by the jaws of the coil spring compressor. 9. Inspect the strut for any binding of the strut shaft over the full stroke of the shaft. 10. Inspect the strut mount and the upper spring seat assembly for any of the following conditions: - Mount for cracks and distortion and retaining studs for any sign of damage. - Severe deterioration of rubber isolator, - Binding strut assembly pivot bearing. If pivot bearing is replaced it is to be installed with the white side of bearing facing up. - Inspect dust shield for rips and/or deterioration. - Inspect jounce bumper for cracks and signs of deterioration. 11. Replace any components of the strut assembly found to be worn or defective during the inspection, before assembling the strut. ASSEMBLE 1. Clamp the strut assembly in a vise, with the strut in a vertical position. When clamping the strut assembly in the vise, do not clamp strut using the Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement > Page 5199 body of the strut only by strut clevis bracket. 2. Install the compressed coil spring onto the strut. Coil spring is to be installed with smaller coil down, so spring correctly seats on strut assembly. 3. Install jounce bumper on the strut shaft. 4. Install dust shield, pivot bearing and upper spring seat as an assembly on the strut. 5. Position upper spring seat alignment notch with clevis bracket on strut assembly. 6. Install strut mount on strut assembly and the strut mount retaining nut on the shaft of the strut assembly. WARNING: The following 2 steps must be completely done before spring compressor, special tool C-4838 is released from the coil spring . 7. Install Socket, Strut Nut, Special Tool L-4558A (or L-4558), or equivalents on the strut shaft retaining nut. Then install a 10 mm socket through the center of the socket and on the hex of the strut shaft. While holding strut shaft from turning, torque strut shaft retaining nut to 75 Nm (55 ft. lbs.). 8. Equally loosen both Spring Compressors, Special Tool C-4838, or equivalent until top coil of spring is fully seated against upper spring seat and strut mount. Then relieve all tension from spring compressors and remove spring compressors from strut assembly spring. Disassembly NOTE: The rear strut unit is not serviced and must be replaced as an assembly if found to be defective. The strut is available with 2 calibrations, be sure strut is replaced with an assembly of the same calibration. COMPONENTS The components of the strut assembly listed below are replaceable if found to be defective. Coil spring (Coil springs come in a standard rate of 120 lbs. per inch be sure spring is replaced with a spring of the same rate.) - Dust shield - Mount assembly - Jounce Bumper - Lower Spring Isolator - Shaft Nut PROCEDURE 1. Remove strut assembly requiring service from the vehicle. 2. Position strut assembly in a vise. Using paint or equivalent, mark the strut unit, lower spring isolator, spring and upper strut mount for indexing of the parts at assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement > Page 5200 3. Position Spring Compressors, Special Tool C-4838, or equivalent on the strut assembly spring. Compress coil spring until all load is removed from upper strut mount assembly. 4. Install Strut Rod Socket, Special Tool, L-4558A or L-4558, or equivalents on strut shaft nut. Inserted a 10 mm socket through special tool and onto end of strut shaft to keep strut shaft from turning. Remove strut shaft nut from strut shaft. 5. Remove washer between strut shaft nut and upper strut mount and isolator. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement > Page 5201 6. Remove upper strut mount assembly from strut shaft and spring. 7. Remove the washer from strut shaft, that is between the strut upper mount assembly and dust shield. 8. Remove the coil spring and spring compressor as an assembly from the strut. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement > Page 5202 9. Remove the dust shield from the strut assembly. 10. Remove the jounce bumper from the shaft of the strut assembly. 11. Remove the coil spring lower isolator from the strut assembly spring seat. 12. Inspect all disassembled components for signs of abnormal wear or failure replacing any components as required. Inspect strut unit for signs of abnormal oil leakage and for loss of gas charge. To check for loss of gas charge in strut unit. Push strut shaft into body of strut and release, strut shaft should return to its fully extended position. If strut shaft does not return to its fully extended position replace strut unit. Assembly Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement > Page 5203 1. Install the original or a new isolator on lower spring seat of strut. 2. Install jounce bumper on strut shaft. 3. Install the dust shield on the strut assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement > Page 5204 4. Lower the coil spring onto the strut unit. Position end of coil spring against edge of spring isolator on lower spring seat of strut assembly. 5. Install washer on strut shaft with raised edge of washer facing upward. 6. Install the strut assembly upper mount onto the strut shaft. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Replacement > Page 5205 7. Install the washer on the strut assembly upper mount. Washer must be installed with the raised edge of the washer facing down. 8. Install the upper strut mount to strut shaft retaining nut. 9. Using Strut Rod Socket, Special Tool, L-4558A, or equivalent and a 10 mm socket to keep strut shaft from turning, torque the strut shaft nut to 61 Nm (45 ft. lbs.). 10. Equally loosen the Spring Compressors, Special Tool C-4838, or equivalent until spring is seated on upper strut mount and all tension is relieved from the spring compressors. 11. Install the strut assembly back into the vehicle. 12. Check and reset rear wheel TOE to specifications if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications Trailing Arm: Specifications Shaft Nut .............................................................................................................................................. ..................................................... 95 Nm (70 ft. lbs.) Bracket To Body Attaching Bolts ............................................................................................................................................................. 95 Nm (70 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 5209 Trailing Arm: Description and Operation The lateral arms and tension strut have rubber isolator bushings at each end. The lateral arms are attached to the rear crossmember and knuckle, using a unique bolt and nut assembly at each end. The lateral arm to rear crossmember attaching bolts are longer than the lateral arm to knuckle attaching bolts. Each lateral arm to knuckle attaching bolt and nut assembly uses 2 flat washers. Each lateral arm to rear crossmember attaching bolt uses 1 flat washer and 1 adjustment cam to provide a means for rear wheel Toe adjustment. The tension strut assembly attaches to a bracket on the frame rail and to the bottom of the knuckle. Lateral arms, tension struts and knuckles are normally replaced only when the part has been damaged or when the vehicle has been involved in an accident. If a suspension part has been damaged, be sure to check the underbody dimensions of the car. If underbody dimensions of the vehicle are not correct, the frame must be straightened before replacement suspension components are installed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 5210 Trailing Arm: Testing and Inspection Inspect the tension strut bushings and retainers for signs of deterioration or damage. If the tension strut bushings are deteriorated or the retainers are damaged, replacement of the tension strut bushings and or the retainers will be required. The bushings and retainers are serviceable as separate components of the tension strut. Inspect the tension strut for signs of contact with the ground or road debris which has bent or caused other damage to the tension strut. If the tension strut is bent or damaged the tension strut will require replacement. Do not attempt to repair or straighten a tension strut. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 5211 Trailing Arm: Service and Repair GENERAL INFORMATION The rear suspension lateral links are only serviced as complete assemblies. The isolator bushings used in the lateral links are not serviced as separate components. The rear lateral link assemblies are unique, having different size bushings to accommodate the rear Toe adjustment cams. The rearward lateral links, must be installed with small bushing sleeve at knuckle and large bushing sleeve at rear crossmember. This is required to accommodate the rear Toe adjustment cam. REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the rear wheel and tire assembly from the side of the vehicle requiring lateral link removal. 3. Remove the nut, bolt and washers attaching the lateral links to the knuckle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 5212 4. Remove nut, bolt, washer and Toe adjustment cam, attaching lateral links requiring removal, from rear crossmember. Then remove lateral links from vehicle. INSTALL Rear lateral links when being installed, must be specifically positioned and orientated on the vehicle. The lateral link having same size bushing sleeves, must be mounted to the crossmember and knuckle toward front of vehicle. The lateral link with different size bushing sleeves, must be mounted to the crossmember and knuckle toward rear of vehicle. The lateral link with small and large bushing sleeves, must be installed with small bushing sleeve at knuckle and large bushing sleeve at rear crossmember. This is required to accommodate the rear Toe adjustment cam at rear crossmember. The lateral link mounting bolts are different lengths, and need to be installed in specific locations and direction on vehicle. The lateral link mounting bolt at knuckle MUST be installed, with head of bolt facing front of vehicle. The lateral link mounting bolt at crossmember MUST be installed, with head of bolt facing rear of vehicle. The long attaching bolt must be used at rear crossmember and short bolt used at knuckle. 1. Install washer on short lateral link attaching bolt. Then install short lateral link attaching bolt, into lateral link having the same size bushing sleeves. Then install lateral link, bolt and washer onto knuckle as an assembly, with head of bolt facing to front of vehicle. 2. Install lateral link with small and large bushing sleeve, on lateral link attaching bolt in rear knuckle. Small bushing sleeve must be installed on bolt in rear knuckle with large bushing sleeve at crossmember of vehicle. 3. Install washer and nut onto lateral link attaching bolt at rear knuckle. Do not tighten the lateral link to rear knuckle attaching bolt at this time. 4. Install Toe adjustment cam on long lateral link attaching bolt. Install long lateral link attaching bolt and adjustment cam, into lateral link toward rear of vehicle, having the large bushing sleeve. Then pass lateral link attaching bolt into rear crossmember. Head of long lateral link to crossmember attaching bolt must face to rear of vehicle when installed. 5. Position forward rear lateral link against rear crossmember. Then pass the lateral link attaching bolt through front lateral link bushing sleeve. 6. Install washer and nut onto lateral link attaching bolt at rear crossmember. Do not tighten the lateral link to rear crossmember attaching bolt at this time. 7. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 8. Lower vehicle to the ground. 9. With suspension supporting total weight of vehicle, and lateral links at correct curb height, torque both lateral link attaching bolts to 95 Nm (70 ft. lbs.). 10. Check and reset rear wheel TOE to specifications if required. Refer to Front And Rear Toe Setting Procedure in Wheel Alignment. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Front To Knuckle Retaining Nut .................................................................................................................... ................................................ 216 Nm (160 ft. lbs.) Rear Hub Nut ............................................................................................................................................... ................................................. 217 Nm (160 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 5217 Wheel Bearing: Fluid Type Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 5218 Wheel Bearing: Service Precautions CAUTION: The hub/bearing retaining nut must be tightened to but must not exceed its required torque specification. The proper torque specification of the retaining nut is critical to the life of the hub bearing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Description and Operation > Front Wheel Bearing: Description and Operation Front The front wheel hub bearing used is a Unit 1 type cartridge bearing. The wheel bearing is serviced separately from the front steering knuckle and front hub assembly. Installation and retention of the front wheel bearing into the steering knuckle, is by means of an interference press fit using a retaining compound and a retaining snap ring. Installation of the front hub into the front wheel bearing, must be done after wheel bearing and retaining snap ring is installed in steering knuckle. The unit 1 wheel bearing is serviced only as a complete assembly less the wheel hub. If the front wheel bearing requires replacement, the hub must be removed from the original wheel bearing and transferred to the replacement bearing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Description and Operation > Front > Page 5221 Wheel Bearing: Description and Operation Rear All vehicles are equipped with permanently lubricated and sealed for life rear wheel bearings. There is no periodic lubrication or maintenance recommended for these units. However, if servicing of a rear wheel bearing is required, refer to procedures in Testing and Inspection and Service and Repair for the inspection and replacement of the rear wheel bearing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Front Wheel Bearing: Testing and Inspection Front NOTE: The hub bearing is designed for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the hub bearing. With the wheel, disc brake caliper. and brake rotor removed, rotate the wheel hub. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the hub bearing exhibits any of these conditions during diagnosis, the hub bearing will require replacement, the bearing is not serviceable. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weapage from the hub bearing is considered normal and should not require replacement of the hub bearing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 5224 Wheel Bearing: Testing and Inspection Rear The rear hub and bearing assembly is designed for the life of the vehicle and should require no maintenance. The following procedure may be used for evaluation of bearing condition. With wheel and brake drum removed, rotate flanged outer ring of hub. Excessive roughness, lateral play or resistance to rotation may indicate dirt intrusion or bearing failure. If the rear wheel bearings exhibit these conditions during inspection, the hub and bearing assembly should be replaced. Damaged bearing seals and resulting excessive grease loss may also require bearing replacement. Moderate grease loss from bearing is considered normal and should not require replacement of the hub and bearing assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Removal 1. Remove the steering knuckle, hub and the hub bearing as an assembly from the vehicle. See: Front Steering Knuckle/Service and Repair NOTE: The removal and installation of the steering knuckle hub bearing is to ONLY be done with the steering knuckle removed from the vehicle. Removal of the hub bearing from the steering knuckle MUST be done using an arbor press and the following procedure. 2. Install Bearing Splitter, Special Tool P334, or equivalent on the steering knuckle and hub/bearing assembly as shown to support steering knuckle when pressing out hub. 3. Position steering knuckle and hub and bearing in an arbor press supported by Bearing Splitter, Special Tool P334 as shown. 4. Position Driver, Special Tool 6644-2, or equivalent on the small end of the hub to drive hub out of bearing. Using arbor press remove hub from bearing. The one bearing race will come out with hub when hub is removed from bearing. 5. Remove Bearing Splitter, Special Tool P334, or equivalent from the steering knuckle. CAUTION: Safety goggles and or face protection should always be worn when removing the snap ring retaining the hub/bearing in the steering knuckle. When the snap ring is removed from the steering knuckle it could fly out of the steering knuckle with great force possibly causing personal injury. 6. Using a screw driver, remove the snap ring retaining the hub bearing in the steering knuckle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5227 7. Place steering knuckle in an arbor press supported by press blocks as shown. Press blocks must not obstruct hub bearing bore in steering knuckle so bearing can be pressed out of knuckle. Place Bearing Driver, Special Tool MB-990799, or equivalent on outer race of hub bearing. Press hub bearing completely out of the steering knuckle. 8. Install Bearing Splitter, Special Tool P334, or equivalent on hub so it is between the flange of the hub and the bearing race remaining on the hub. Place hub, bearing race and the bearing splitter in an arbor press as shown. Place Driver, Special Tool 6644-2, or equivalent on end of hub. Press the hub out of the bearing race. Installation 1. Wipe bore of steering knuckle clean of any grease or dirt with a clean dry shop towel. CAUTIONS: Do not use any type of solvent on the hub bearing when cleaning it. - The hub bearing must be wiped as clean as possible. Any remaining rust preventative on the bearing can effect the bonding action of the adhesive to the bearing. 2. Clean the rust preventative from the replacement hub bearing using a clean dry shop towel. CAUTION: When applying adhesive to bore of steering knuckle, do not allow adhesive to get into the snap ring in bore or on the seal of the hub bearing 3. Apply Loctite Adhesive #640 or an equivalent, to the bore of the steering knuckle. The adhesive is to be applied to the entire bore wall surface, from the shoulder at the bottom to just below the snap ring groove. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5228 4. Place new hub bearing into bore of steering knuckle so it is square with the bore. Place steering knuckle in arbor press with Receiver, Special Tool C-4698-2, or equivalent supporting steering knuckle. Place Diver, Special Tool 5052, or equivalent on outer race of the hub bearing. Press hub bearing into steering knuckle until it is fully bottom in bearing bore of steering knuckle. CAUTION: When installing the retaining snap ring for the hub bearing care must be taken not to damage seal on new hub bearing. 5. Install hub bearing retaining snap ring into snap ring groove in hub bearing bore of steering knuckle. Be sure snap ring is fully seated in snap ring groove. 6. Place steering knuckle with hub bearing installed in an arbor press with Receiver, Special Tool MB-990799, or equivalent supporting inner race of the hub bearing. Place hub in nub bearing making sure it is square with bearing. Place Driver, Special Tool 6522, or equivalent on front face of hub. Press the hub into the hub bearing until hub is fully bottomed in hub bearing. 7. Install the steering knuckle, hub and the hub bearing as an assembly on the vehicle. See: Front Steering Knuckle/Service and Repair 8. Install the wheel and tire on the vehicle. 9. Lower the vehicle. 10. Set the front wheel Toe to the required specification. CAUTION: After the vehicle is aligned it can only be moved a short distance and then parked. Do not move the vehicle any further until the adhesive has cured for a minimum of two hours. Driving the vehicle before the adhesive is allowed to cure properly, will affect the retention of the bearing in the bore of the steering knuckle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5229 Wheel Bearing: Service and Repair Rear REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. On vehicles equipped with rear drum brakes, remove brake drum from rear hub/bearing assembly. On vehicles equipped with rear disc brakes, remove disc brake caliper from disc brake adapter, and then remove rotor from hub/ bearing assembly. Rear Hub And Bearing Dust Cap 4. Remove dust cap. from rear hub/bearing assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5230 5. Remove hub/bearing assembly to rear spindle retaining nut. 6. Remove rear hub/bearing assembly from rear spindle by pulling straight of spindle by hand. INSTALL CAUTION: The hub/bearing retaining nut must be tightened to but must not exceed its required torque specification. The proper torque specification of the retaining nut is critical to the life of the hub bearing. 1. Position hub/bearing assembly on rear spindle. 2. Install a new hub nut and tighten to a torque of 217 Nm (160 ft. lbs.). 3. Install dust cap; using a soft faced hammer. 4. On drum brake equipped vehicles, install rear brake drum on hub/bearing assembly. On vehicles equipped with rear disc brakes, install rotor on hub/ bearing assembly. Caliper Assembly Guide Pin Bolts 5. On disc brake equipped vehicles install disc brake caliper on disc brake adapter. Install the 2 caliper guide pin bolts and torque to 22 Nm (192 in. lbs.). Refer To Disc Brake Caliper Service and Repair. 6. Install rear wheel and tire assembly on vehicle. Tighten all wheel stud nuts in crisscross pattern to one-half specified torque. Then repeat pattern, fully tightening stud nuts to 109 - 150 Nm (80 - 110 ft. lbs.). 7. Lower vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 5240 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 5246 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 5247 Axle Nut: Specifications Front Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 183 Nm (135 ft. lbs.) Rear Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 217 Nm (160 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation The temporary spare tire is designed for emergency use only. The original tire should be repaired and reinstalled at the first opportunity, or replaced with a new. Do not exceed speeds of 50 MPH when the temporary spare tire is in use on the vehicle. Refer to the Owner's Manual for complete details. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Tire & Wheel - Runout Wheels: Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5257 Wheels: Specifications Lug Nuts .............................................................................................................................................. ................................. 109 - 150 Nm (80 - 110 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5258 Wheels: Description and Operation Original equipment wheels are designed for proper operation at all loads up to the specified maximum vehicle capacity. All models use steel or cast aluminum drop center wheels. Every wheel has raised sections between the rim flanges and rim drop well called safety humps. Initial inflation of the tires forces the bead over these raised sections. In case of air loss the raised sections help hold the tire in position on the wheel until the vehicle can be brought to a safe stop. Cast aluminum wheels require special balance weights to fit on the thicker flange of the rim and special wheel clamps for the alignment equipment. The wheel studs and nuts are designed for specific wheel applications and must be replaced with equivalent parts. Do not use replacement parts of lesser quality or of a substitute design. All aluminum wheels use wheel nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Vehicles that are equipped with bolt-on wheel covers use large nose wheel nuts. The wheel nuts used on a vehicle equipped with bolt-on wheel covers are externally threaded so that the wheel covers can be attached to the wheel nuts. Before installing a wheel, remove any buildup of corrosion on the wheel mounting surface. WARNING: Installing wheels without good metal-to-metal contact could cause loosening of wheel lug nuts. This could adversely affect the safety and handling of your vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5259 Wheels: Testing and Inspection Wheels must be replaced if they: - Have excessive run out - Are bent or dented - Leak air - Have damaged wheel lug/ nut holes Wheel repairs employing hammering, heating, welding or repairing leaks are not allowed. Original equipment replacement wheels should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The physical dimensions (diameter, width, offset, pilot hole and bolt circle) of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. Replacement with used wheels is not recommended. The service history of the rim may have included severe treatment or very high mileage. The rim could fail without warning. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5260 Wheels: Service and Repair Lug Nut Tightening Sequence To install the wheel and tire assembly, first position it properly on the mounting surface using the hub pilot as a guide. Then progressively tighten the lug nuts in the proper sequence to half of the required torque. Finally tighten the lug nuts in the proper sequence to 109 - 150 Nm (80 - 110 ft. lbs.). Never use oil or grease on studs or nuts. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Front To Knuckle Retaining Nut .................................................................................................................... ................................................ 216 Nm (160 ft. lbs.) Rear Hub Nut ............................................................................................................................................... ................................................. 217 Nm (160 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 5265 Wheel Bearing: Fluid Type Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 5266 Wheel Bearing: Service Precautions CAUTION: The hub/bearing retaining nut must be tightened to but must not exceed its required torque specification. The proper torque specification of the retaining nut is critical to the life of the hub bearing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front Wheel Bearing: Description and Operation Front The front wheel hub bearing used is a Unit 1 type cartridge bearing. The wheel bearing is serviced separately from the front steering knuckle and front hub assembly. Installation and retention of the front wheel bearing into the steering knuckle, is by means of an interference press fit using a retaining compound and a retaining snap ring. Installation of the front hub into the front wheel bearing, must be done after wheel bearing and retaining snap ring is installed in steering knuckle. The unit 1 wheel bearing is serviced only as a complete assembly less the wheel hub. If the front wheel bearing requires replacement, the hub must be removed from the original wheel bearing and transferred to the replacement bearing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front > Page 5269 Wheel Bearing: Description and Operation Rear All vehicles are equipped with permanently lubricated and sealed for life rear wheel bearings. There is no periodic lubrication or maintenance recommended for these units. However, if servicing of a rear wheel bearing is required, refer to procedures in Testing and Inspection and Service and Repair for the inspection and replacement of the rear wheel bearing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Wheel Bearing: Testing and Inspection Front NOTE: The hub bearing is designed for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the hub bearing. With the wheel, disc brake caliper. and brake rotor removed, rotate the wheel hub. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the hub bearing exhibits any of these conditions during diagnosis, the hub bearing will require replacement, the bearing is not serviceable. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weapage from the hub bearing is considered normal and should not require replacement of the hub bearing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 5272 Wheel Bearing: Testing and Inspection Rear The rear hub and bearing assembly is designed for the life of the vehicle and should require no maintenance. The following procedure may be used for evaluation of bearing condition. With wheel and brake drum removed, rotate flanged outer ring of hub. Excessive roughness, lateral play or resistance to rotation may indicate dirt intrusion or bearing failure. If the rear wheel bearings exhibit these conditions during inspection, the hub and bearing assembly should be replaced. Damaged bearing seals and resulting excessive grease loss may also require bearing replacement. Moderate grease loss from bearing is considered normal and should not require replacement of the hub and bearing assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Removal 1. Remove the steering knuckle, hub and the hub bearing as an assembly from the vehicle. See: Steering/Front Steering Knuckle/Service and Repair NOTE: The removal and installation of the steering knuckle hub bearing is to ONLY be done with the steering knuckle removed from the vehicle. Removal of the hub bearing from the steering knuckle MUST be done using an arbor press and the following procedure. 2. Install Bearing Splitter, Special Tool P334, or equivalent on the steering knuckle and hub/bearing assembly as shown to support steering knuckle when pressing out hub. 3. Position steering knuckle and hub and bearing in an arbor press supported by Bearing Splitter, Special Tool P334 as shown. 4. Position Driver, Special Tool 6644-2, or equivalent on the small end of the hub to drive hub out of bearing. Using arbor press remove hub from bearing. The one bearing race will come out with hub when hub is removed from bearing. 5. Remove Bearing Splitter, Special Tool P334, or equivalent from the steering knuckle. CAUTION: Safety goggles and or face protection should always be worn when removing the snap ring retaining the hub/bearing in the steering knuckle. When the snap ring is removed from the steering knuckle it could fly out of the steering knuckle with great force possibly causing personal injury. 6. Using a screw driver, remove the snap ring retaining the hub bearing in the steering knuckle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5275 7. Place steering knuckle in an arbor press supported by press blocks as shown. Press blocks must not obstruct hub bearing bore in steering knuckle so bearing can be pressed out of knuckle. Place Bearing Driver, Special Tool MB-990799, or equivalent on outer race of hub bearing. Press hub bearing completely out of the steering knuckle. 8. Install Bearing Splitter, Special Tool P334, or equivalent on hub so it is between the flange of the hub and the bearing race remaining on the hub. Place hub, bearing race and the bearing splitter in an arbor press as shown. Place Driver, Special Tool 6644-2, or equivalent on end of hub. Press the hub out of the bearing race. Installation 1. Wipe bore of steering knuckle clean of any grease or dirt with a clean dry shop towel. CAUTIONS: Do not use any type of solvent on the hub bearing when cleaning it. - The hub bearing must be wiped as clean as possible. Any remaining rust preventative on the bearing can effect the bonding action of the adhesive to the bearing. 2. Clean the rust preventative from the replacement hub bearing using a clean dry shop towel. CAUTION: When applying adhesive to bore of steering knuckle, do not allow adhesive to get into the snap ring in bore or on the seal of the hub bearing 3. Apply Loctite Adhesive #640 or an equivalent, to the bore of the steering knuckle. The adhesive is to be applied to the entire bore wall surface, from the shoulder at the bottom to just below the snap ring groove. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5276 4. Place new hub bearing into bore of steering knuckle so it is square with the bore. Place steering knuckle in arbor press with Receiver, Special Tool C-4698-2, or equivalent supporting steering knuckle. Place Diver, Special Tool 5052, or equivalent on outer race of the hub bearing. Press hub bearing into steering knuckle until it is fully bottom in bearing bore of steering knuckle. CAUTION: When installing the retaining snap ring for the hub bearing care must be taken not to damage seal on new hub bearing. 5. Install hub bearing retaining snap ring into snap ring groove in hub bearing bore of steering knuckle. Be sure snap ring is fully seated in snap ring groove. 6. Place steering knuckle with hub bearing installed in an arbor press with Receiver, Special Tool MB-990799, or equivalent supporting inner race of the hub bearing. Place hub in nub bearing making sure it is square with bearing. Place Driver, Special Tool 6522, or equivalent on front face of hub. Press the hub into the hub bearing until hub is fully bottomed in hub bearing. 7. Install the steering knuckle, hub and the hub bearing as an assembly on the vehicle. See: Steering/Front Steering Knuckle/Service and Repair 8. Install the wheel and tire on the vehicle. 9. Lower the vehicle. 10. Set the front wheel Toe to the required specification. CAUTION: After the vehicle is aligned it can only be moved a short distance and then parked. Do not move the vehicle any further until the adhesive has cured for a minimum of two hours. Driving the vehicle before the adhesive is allowed to cure properly, will affect the retention of the bearing in the bore of the steering knuckle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5277 Wheel Bearing: Service and Repair Rear REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. On vehicles equipped with rear drum brakes, remove brake drum from rear hub/bearing assembly. On vehicles equipped with rear disc brakes, remove disc brake caliper from disc brake adapter, and then remove rotor from hub/ bearing assembly. Rear Hub And Bearing Dust Cap 4. Remove dust cap. from rear hub/bearing assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5278 5. Remove hub/bearing assembly to rear spindle retaining nut. 6. Remove rear hub/bearing assembly from rear spindle by pulling straight of spindle by hand. INSTALL CAUTION: The hub/bearing retaining nut must be tightened to but must not exceed its required torque specification. The proper torque specification of the retaining nut is critical to the life of the hub bearing. 1. Position hub/bearing assembly on rear spindle. 2. Install a new hub nut and tighten to a torque of 217 Nm (160 ft. lbs.). 3. Install dust cap; using a soft faced hammer. 4. On drum brake equipped vehicles, install rear brake drum on hub/bearing assembly. On vehicles equipped with rear disc brakes, install rotor on hub/ bearing assembly. Caliper Assembly Guide Pin Bolts 5. On disc brake equipped vehicles install disc brake caliper on disc brake adapter. Install the 2 caliper guide pin bolts and torque to 22 Nm (192 in. lbs.). Refer To Disc Brake Caliper Service and Repair. 6. Install rear wheel and tire assembly on vehicle. Tighten all wheel stud nuts in crisscross pattern to one-half specified torque. Then repeat pattern, fully tightening stud nuts to 109 - 150 Nm (80 - 110 ft. lbs.). 7. Lower vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 220396 > Oct > 96 > Wheel Covers Noisy/Missing/Loose Wheel Cover: Customer Interest Wheel Covers - Noisy/Missing/Loose NO: 22-03-96 GROUP: Wheels DATE: Oct. 4, 1996 SUBJECT: Noisy, Loose Or Missing Bolt-on Wheel Covers MODELS: 1997 (PL) Neon SYMPTOM/CONDITION: Noisy, loose or missing wheel covers due to loose or missing wheel cover nuts. DIAGNOSIS: Inspect each wheel cover nut and determine if loose. If the plastic nut is over-torqued, it will result in a jumped thread and become loose. If the plastic nut has jumped a thread torque nut to 55 in. lbs. Inspect the nut, if the nut is loose remove and inspect for damage. If one or more of the 5 nuts is damaged proceed to the repair procedure. If nut is now secure no further action is required. PARTS REQUIRED: AR 04656777 Wheel Cover And Nut Assembly (Sales Code W4W) AR 04656376 Wheel Cover And Nut Assembly (Sales Code W4Y) AR 04656825 Wheel Cover And Nut Assembly (Sales Code W4J) AR 04656251 Wheel Cover And Nut Assembly (Sales Code W4C) REPAIR PROCEDURE: This bulletin provides the procedure for the wheel cover installation. 1. Place wheel cover on wheel and firmly push down on center cap so that it is flat against the wheel. CAUTION: THE WHEEL COVER ATTACHING NUTS SHOULD NEVER BE INSTALLED BY DRIVING THE NUT ONTO THE WHEEL NUT WITH A RUBBER MALLET OR BY USING AN IMPACT WRENCH. PLEASE INSURE THAT THE NEW VEHICLE PREP TECHNICIAN IS AWARE OF THIS INFORMATION. 2. Hand tighten the wheel cover nuts until they begin to "ratchet" and then let the cover spring back. 3. Torque the wheel cover nuts sequentially to between 45 to 55 in. lbs. CAUTION: THE WHEEL COVER NUT HAS A BUILT IN SAFEGUARD THAT WILL ALLOW THE NUT TO JUMP A THREAD IF OVER-TORQUED. IF THIS CONDITION OCCURS, IT THE NUT SHOULD BE TIGHTENED TO JUST BEFORE THE "JUMP" FEATURE. THE "JUMP" FEATURE CAN BE FELT AS A POP WHEN THE NUT IS TORQUED OVER 55 IN. LBS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 22-20-01-93 0.2 Hrs. Inspect and Torque Wheel Cover - One or All FAILURE CODE: XX - Service Adjustment Labor Operation No: 22-20-01-94 0.2 Hrs. Replace Wheel Cover - One or All FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 220396 > Oct > 96 > Wheel Covers Noisy/Missing/Loose Wheel Cover: All Technical Service Bulletins Wheel Covers - Noisy/Missing/Loose NO: 22-03-96 GROUP: Wheels DATE: Oct. 4, 1996 SUBJECT: Noisy, Loose Or Missing Bolt-on Wheel Covers MODELS: 1997 (PL) Neon SYMPTOM/CONDITION: Noisy, loose or missing wheel covers due to loose or missing wheel cover nuts. DIAGNOSIS: Inspect each wheel cover nut and determine if loose. If the plastic nut is over-torqued, it will result in a jumped thread and become loose. If the plastic nut has jumped a thread torque nut to 55 in. lbs. Inspect the nut, if the nut is loose remove and inspect for damage. If one or more of the 5 nuts is damaged proceed to the repair procedure. If nut is now secure no further action is required. PARTS REQUIRED: AR 04656777 Wheel Cover And Nut Assembly (Sales Code W4W) AR 04656376 Wheel Cover And Nut Assembly (Sales Code W4Y) AR 04656825 Wheel Cover And Nut Assembly (Sales Code W4J) AR 04656251 Wheel Cover And Nut Assembly (Sales Code W4C) REPAIR PROCEDURE: This bulletin provides the procedure for the wheel cover installation. 1. Place wheel cover on wheel and firmly push down on center cap so that it is flat against the wheel. CAUTION: THE WHEEL COVER ATTACHING NUTS SHOULD NEVER BE INSTALLED BY DRIVING THE NUT ONTO THE WHEEL NUT WITH A RUBBER MALLET OR BY USING AN IMPACT WRENCH. PLEASE INSURE THAT THE NEW VEHICLE PREP TECHNICIAN IS AWARE OF THIS INFORMATION. 2. Hand tighten the wheel cover nuts until they begin to "ratchet" and then let the cover spring back. 3. Torque the wheel cover nuts sequentially to between 45 to 55 in. lbs. CAUTION: THE WHEEL COVER NUT HAS A BUILT IN SAFEGUARD THAT WILL ALLOW THE NUT TO JUMP A THREAD IF OVER-TORQUED. IF THIS CONDITION OCCURS, IT THE NUT SHOULD BE TIGHTENED TO JUST BEFORE THE "JUMP" FEATURE. THE "JUMP" FEATURE CAN BE FELT AS A POP WHEN THE NUT IS TORQUED OVER 55 IN. LBS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 22-20-01-93 0.2 Hrs. Inspect and Torque Wheel Cover - One or All FAILURE CODE: XX - Service Adjustment Labor Operation No: 22-20-01-94 0.2 Hrs. Replace Wheel Cover - One or All FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Page 5292 Wheel Cover: Description and Operation A lock-on type wheel cover is used on certain models. The wheel cover is locked to the wheel using the 5 nuts located in the wheel cover. The nuts in the wheel cover, thread onto a special externally threaded wheel nut. This is the method used to retain the wheel cover to the wheel. The wheel cover retaining nut is retained in the wheel cover and will stay on the wheel cover when unthreaded from the wheel nut. If required, the retaining nut for the lock-on wheel cover can be removed from the wheel cover and replaced as a separate part of the lock-on wheel cover. The lock-on wheel cover can not be removed from the wheel until all 5 of wheel cover retaining nuts are unthreaded from the wheel nuts. Then the lock-on wheel cover can be removed by hand from the wheel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Wheel Cover Replacement Wheel Cover: Service and Repair Wheel Cover Replacement NOTE: When unthreading the wheel cover retaining nuts from the wheel nuts it is recommended that a hand wrench be used and not an impact wrench. Use of an impact wrench could result in damage to the lock-on wheel cover retaining nuts. REMOVE 1. Unthread the 5 nuts attaching the wheel cover to the wheel nuts. 2. Grasp the wheel cover and pull straight outward from the wheel. This will remove the wheel cover from the wheel. Fig. 2 INSTALL 1. Align the valve notch in the wheel cover with the valve stem on the wheel. Align the wheel cover retaining nuts with the externally threaded wheel nuts. 2. By hand, start to thread all 5 of the wheel cover retaining nuts onto the externally threaded wheel nuts. NOTE: When tightening the wheel cover retaining nuts it is recommended that a hand wrench be used and not an impact wrench. Use of an impact wrench could result in damage to the lock-on wheel cover retaining nuts. 3. Tighten each of the wheel cover retaining nuts. If the retaining nut "jumps" a thread (slips), which is an override feature of the retaining nut, retighten the retaining nut to a point just prior to this occurring. To avoid rattling of the wheel cover be sure all five retaining nuts are correctly tightened. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Wheel Cover Replacement > Page 5295 Wheel Cover: Service and Repair Wheel Cover Retaining Nut Replacement NOTE: If a retaining nut for the lock-on wheel is damaged, it can be replaced as a separate part of the wheel cover. Use the following procedure for replacing a wheel cover retaining nut. REMOVE 1. If required, remove the wheel cover from the wheel. NOTE: The retaining nut flange can not be forced past the large retaining tab. When removing retaining nut from wheel cover, the flange on the retaining nut must be forced past the 2 small retaining tabs on wheel cover. 2. From the back side of the wheel cover, push outward and tilt the retaining nut sideways forcing the flange on the retaining nut past the 2 small retaining tabs in the retaining nut hole of the wheel cover. 3. When flange on retaining nut is past the 2 retaining tabs on the wheel cover, remove retaining nut from wheel cover by pushing or pulling from hole in wheel cover. INSTALL 1. Install retaining nut in hole of wheel cover with retaining nut flange positioned under the large retaining flange. 2. Push on hex of retaining nut forcing the retaining nut flange past the 2 small retaining tabs in wheel cover. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 5305 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 5311 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 5312 Axle Nut: Specifications Front Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 183 Nm (135 ft. lbs.) Rear Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 217 Nm (160 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence Wheel Fastener: Specifications Wheel Tightening Sequence Wheel Torque Sequence - Master Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 5317 Wheel Fastener: Specifications Lug Nut Torque Lug Nuts .............................................................................................................................................. ................................. 109 - 150 Nm (80 - 110 ft. lbs.) Lug Nut Hex Size ............................................. ........................................................................................................................................................... 19 mm Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 5318 Wheel Fastener: Specifications Wheel Stud Size Stud Size ............................................................................................................................................. ............................................................ M12 x 1.5 mm Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 5319 Wheel Fastener: Description and Operation If wheel attaching studs need to be replaced in the hub and bearing assembly the studs CAN NOT be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. The hub and bearing assembly does not require removal from the steering knuckle or the rear knuckle to replace the wheel attaching studs in the hub and bearing assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 5320 Wheel Fastener: Service and Repair CAUTION: If wheel attaching stud needs to be replaced in the hub and bearing assembly the studs CAN NOT be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. NOTES: - The following procedure and special tools shown MUST be used when replacing wheel attaching studs. - The hub and bearing assembly does not require removal from the steering knuckle to replace wheel attaching studs in the hub and bearing assembly. REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the front wheel and tire assembly from the vehicle. 3. Remove front disc brake caliper to steering knuckle attaching bolts. 4. Remove disc brake caliper assembly from steering knuckle. Caliper is removed by first lifting bottom of caliper away from steering knuckle, and then removing top of caliper out from under steering knuckle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 5321 5. Support the brake caliper assembly using a wire hook, not by the hydraulic flex hose. 6. Remove the braking disc from the front hub. 7. Install a lug nut on wheel stud to be removed from hub and bearing assembly, so threads on stud are even with end of lug nut. Rotate hub so stud requiring removal is aligned with notch cast into front of steering knuckle. Install Remover, Special Tool C-4150, or equivalent on hub and bearing assembly flange and wheel stud. 8. Tighten down on special tool, pushing wheel stud out of the hub and bearing assembly flange. When shoulder of wheel stud is past flange remove special tool from hub and bearing assembly. Remove lug nut from stud and remove wheel stud from flange. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 5322 INSTALL 1. Install replacement wheel stud into flange of hub and bearing assembly. Install washers and wheel lug nut on stud, with flat side of lug nut against washers. 2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing assembly. When the head of the stud is fully seated against the bearing flange, remove lug nut and washers from wheel stud. 3. Install braking disk back on front hub. 4. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding top of caliper under top abutment on steering knuckle. Then installing bottom of caliper against bottom abutment of steering knuckle. 5. Install the disc brake caliper assembly to steering knuckle attaching bolts and torque to 31 Nm (23 ft. lbs.). 6. Install front wheel and tire assembly. Install front wheel lug nuts and torque to 135 Nm (100 ft. lbs.). 7. Lower vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation Air Door Actuator / Motor: Description and Operation The recirculation door actuator is a vacuum controlled actuator used to control movement of the recirculation door in air conditioned equipped vehicles. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Page 5328 Air Door Actuator / Motor: Service and Repair NOTE: The instrument panel must be removed from the vehicle to gain access to the recirculation door actuator. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair REMOVAL 1. Remove instrument panel from vehicle. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair Recirculation Door Actuator 2. Disconnect vacuum line from actuator. 3. Remove two nuts retaining vacuum actuator to recirculation door housing. 4. Disconnect actuator from recirc. door link. 5. Remove recirculation door actuator from vehicle. INSTALLATION For installation reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Adjustments > Mode Control Cable Adjustment Air Door Cable: Adjustments Mode Control Cable Adjustment 1. Attach cable to actuator arm on mode door and clip black casing against the stop. 2. Attach other end of cable to instrument panel control. 3. Turn the mode knob completely counterclockwise. 4. While holding the knob in the counterclockwise position, pull on the black casing of the mode cable. This will take up any free play in the cable and index the mode door to the mode knob. 5. Then snap the cable hold down clip into position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Adjustments > Mode Control Cable Adjustment > Page 5333 Air Door Cable: Adjustments Temperature Control Cable Adjustment 1. Attach cable to actuator arm on temperature door and clip black casing against the stop. 2. Attach other end of cable to instrument panel control. 3. Turn the temperature knob completely counterclockwise. 4. While holding the knob in the counterclockwise position pull on the black casing of the temperature cable. This will take up any free play in the cable and index the temperature door to the temperature knob. 5. Then snap the cable hold down clip into position. 6. Remount control. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Control Cable Replacement Air Door Cable: Service and Repair Mode Control Cable Replacement NOTE: The Mode Control Cable can be removed and installed without having to remove the instrument panel from the vehicle. REMOVAL 1. Remove instrument panel upper cowl panel. Bezel Removal 2. Remove right side upper instrument panel bezel. Instrument Panel Center Vent 3. Remove center vent duct. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Control Cable Replacement > Page 5336 Instrument Panel Defrost Duct 4. Remove upper defrost duct. Instrument Panel Inner Defrost Duct Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Control Cable Replacement > Page 5337 5. Remove inner defrost duct. 6. Disconnect cable at heater unit. 7. Disconnect cable at control panel. 8. Remove cable from vehicle. INSTALLATION For installation, reverse the above procedures, adjust cable and test. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Control Cable Replacement > Page 5338 Air Door Cable: Service and Repair Temperature Control Cable Replacement NOTE: The Control Cable can be removed and installed without having to remove the instrument panel from the vehicle. REMOVAL 1. Remove instrument panel upper cowl panel. Bezel Removal 2. Remove right side upper instrument panel bezel. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair Instrument Panel Center Vent 3. Remove center vent duct. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Control Cable Replacement > Page 5339 Instrument Panel Defrost Duct 4. Remove upper defrost duct. Instrument Panel Inner Defrost Duct Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Control Cable Replacement > Page 5340 5. Remove inner defrost duct. 6. Disconnect cable at heater unit. 7. Disconnect cable at control panel. Remove control from instrument panel. 8. Remove cable from vehicle. INSTALLATION For installation reverse the above procedures, adjust cable and test. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 240397 > Mar > 97 > Blower Motor - Inoperative In Freezing Temps Blower Motor: Customer Interest Blower Motor - Inoperative In Freezing Temps NO: 24-03-97 GROUP: Heating & A/C DATE: Mar. 14, 1997 SUBJECT: Blower Motor Does Not Operate In Freezing Temperatures THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-20-96 DATED DECEMBER 20, 1996, WHICH SHOULD BE NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). A BLOWER MOTOR FOR A/C EQUIPPED VEHICLES HAS BEEN ADDED. MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT AFTER JULY 1, 1994 (MDH 07-01-XX), OR VEHICLES BUILT PRIOR TO JULY 1, 1994 (MDH 07-01-XX) THAT HAVE HAD TECHNICAL SERVICE BULLETIN 23-48-94 PERFORMED. TECHNICAL SERVICE BULLETIN 23-48-94 INCLUDES THE INSTALLATION OF A DRAIN TUBE. SYMPTOM/CONDITION: Blower motor may be inoperable in temperatures at/or below freezing. DIAGNOSIS: Inspect the blower motor fuse. If blown, inspect the blower motor for presence of ice or water. It may be necessary to park the vehicle in a warm area to allow the blower motor to begin to thaw and water to run out to verify the failure mode. If water or ice is found perform the Repair Procedure. PARTS REQUIRED: **AR(1) 04644918 Blower Motor (With Air Conditioning)** AR(1) 04644545 Blower Motor (Without Air Conditioning) AR(1) 04687835 Fuse, Blower Motor AR(1) 04783100 Drain Tube REPAIR PROCEDURE: This bulletin involves the positioning of the drain tube assembly and the replacement of the blower motor and blower motor fuse. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 240397 > Mar > 97 > Blower Motor - Inoperative In Freezing Temps > Page 5349 1. The drain tube is located up under the instrument panel to the left of the steering column. The tube should be routed as shown in Figure 1. 2. If the drain tube is pushed over or pinched as shown in Figure 2, pull the lower end of the drain and route as shown in Figure 1. If the drain tube will not straighten out to allow repositioning, the drain tube must be replaced. 3. Insure that the end of the drain tube is properly located down into the sill as far as possible without kinking the tube. 4. Replace the blower motor/wheel assembly by following the procedure in the 1997 Neon Service Manual (Publication Number 81-270-7025) starting on page 24-18. NOTE: THE BLOWER MOTOR RESISTOR AND CONNECTOR SHOULD BE CHECKED FOR SIGNS OF DAMAGE AND REPAIRED/REPLACED AS NEEDED. 5. Replace the blower motor fuse and insure blower motor is now operating properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-55-01-93 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 240397 > Mar > 97 > Blower Motor - Inoperative In Freezing Temps Blower Motor: All Technical Service Bulletins Blower Motor - Inoperative In Freezing Temps NO: 24-03-97 GROUP: Heating & A/C DATE: Mar. 14, 1997 SUBJECT: Blower Motor Does Not Operate In Freezing Temperatures THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-20-96 DATED DECEMBER 20, 1996, WHICH SHOULD BE NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). A BLOWER MOTOR FOR A/C EQUIPPED VEHICLES HAS BEEN ADDED. MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT AFTER JULY 1, 1994 (MDH 07-01-XX), OR VEHICLES BUILT PRIOR TO JULY 1, 1994 (MDH 07-01-XX) THAT HAVE HAD TECHNICAL SERVICE BULLETIN 23-48-94 PERFORMED. TECHNICAL SERVICE BULLETIN 23-48-94 INCLUDES THE INSTALLATION OF A DRAIN TUBE. SYMPTOM/CONDITION: Blower motor may be inoperable in temperatures at/or below freezing. DIAGNOSIS: Inspect the blower motor fuse. If blown, inspect the blower motor for presence of ice or water. It may be necessary to park the vehicle in a warm area to allow the blower motor to begin to thaw and water to run out to verify the failure mode. If water or ice is found perform the Repair Procedure. PARTS REQUIRED: **AR(1) 04644918 Blower Motor (With Air Conditioning)** AR(1) 04644545 Blower Motor (Without Air Conditioning) AR(1) 04687835 Fuse, Blower Motor AR(1) 04783100 Drain Tube REPAIR PROCEDURE: This bulletin involves the positioning of the drain tube assembly and the replacement of the blower motor and blower motor fuse. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 240397 > Mar > 97 > Blower Motor - Inoperative In Freezing Temps > Page 5355 1. The drain tube is located up under the instrument panel to the left of the steering column. The tube should be routed as shown in Figure 1. 2. If the drain tube is pushed over or pinched as shown in Figure 2, pull the lower end of the drain and route as shown in Figure 1. If the drain tube will not straighten out to allow repositioning, the drain tube must be replaced. 3. Insure that the end of the drain tube is properly located down into the sill as far as possible without kinking the tube. 4. Replace the blower motor/wheel assembly by following the procedure in the 1997 Neon Service Manual (Publication Number 81-270-7025) starting on page 24-18. NOTE: THE BLOWER MOTOR RESISTOR AND CONNECTOR SHOULD BE CHECKED FOR SIGNS OF DAMAGE AND REPAIRED/REPLACED AS NEEDED. 5. Replace the blower motor fuse and insure blower motor is now operating properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-55-01-93 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 5356 Blower Motor: Locations The blower motor is located on the bottom right side of the evaporator case unit housing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Circuit Operation Blower Motor: Description and Operation Circuit Operation CIRCUIT OPERATION With the ignition switch in the RUN position, power flows from the 25 Amp fuse, in cavity 7 of the fuse block, to the blower motor. Blower motor speed is controlled by the fan control switch located in the instrument panel, and the resistor block. Blower motor LOW speed operation is accomplished on the C4 circuit. When the control switch is moved to the LOW speed position, current is passed on the C7 circuit through the blower motor resistor to the C4 circuit. It then flows through the blower motor switch to the Z8 circuit. The Z8 circuit terminates at a grounding point on the instrument panel left center support. The operation of the blower motor M1 and M2 speed operations is the same as the LOW speed except, the C5 circuit is used for the M1 speed and circuit C6 is used for M2 speed operation. Blower motor HIGH speed operation is accomplished on the C7 circuit which supplies battery voltage directly to the blower motor. There are no resistors used in the HIGH speed mode. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Circuit Operation > Page 5359 Blower Motor: Description and Operation System Operation BLOWER MOTOR OPERATION With the ignition switch in the RUN position, power flows from the 25 amp fuse, in cavity 7 of the fuse block, to the blower motor. Blower motor speed is controlled by the fan control switch located in the instrument panel, and by the resistor block. Blower motor low-speed operation is accomplished on the C4 circuit. When the control switch is moved to the low-speed position, current flows from the C7 circuit, through the blower motor resistor, to the C4 circuit. It then flows through the blower motor switch to the Z8 circuit. The Z8 circuit terminates at a grounding point located at the instrument panel left center support. The operation of the blower motor M1 and M2 speed operations is the same as the low-speed except that circuit C5 is used for the M1 speed, and circuit C6 is used for M2 speed operation. Blower motor high-speed operation is accomplished on the C7 circuit, which supplies battery voltage directly to the blower motor There are no resistors used in the high-speed mode. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and Inspection > Flow of Diagnosis Blower Motor: Flow of Diagnosis Blower Motor Noise and Vibration Diagnosis Blower Motor Noise/Vibration Diagnosis The resistor block supplies the blower motor with varied voltage (low and middle speeds) or battery voltage (high speed). CAUTION: Blower motor resistor block can be very hot, use caution when working on or near it. Do not operate the blower motor with the resistor block removed from the heater-A/C housing. Refer to the Blower Motor Vioration/Noise chart for diagnosis. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and Inspection > Flow of Diagnosis > Page 5362 Blower Motor Electrical Diagnosis Blower Motor Electrical Diagnosis For Blower motor electrical diagnosis refer to the above chart and also see Diagrams/Electrial. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and Inspection > Flow of Diagnosis > Page 5363 Blower Motor: Component Tests and General Diagnostics - Check the 30 Amp fuse located in the PDC for the radiator fan motor - Check the 15 Amp fuse located in cavity 10 of the fuse block for the A/C compressor clutch relay - Check the 10 Amp fuse located in the PDC for the A/C compressor clutch relay. - Check the 25 Amp fuse located in cavity 7 of the fuse block for the blower motor. - Check the right headlamp ground located at the right fender side shield. - Check the left headlamp ground located on the left side of the radiator closure panel. - On vehicles equipped with A/C check the refrigerant level. The system will not operate with a low level of refrigerant. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > With A/C Blower Motor: Service and Repair With A/C NOTE: The blower motor can be removed from the vehicle without having to remove the unit housing assembly REMOVAL 1. Remove right side scuff plate. 2. Pull back carpet. 3. Cut wheel housing silencer in line with blower motor wiring. 4. Disconnect blower motor wiring connector. 5. Right Hand Drive (RHD) vehicle remove the motor cover. Blower Motor Retaining Screws 6. Remove three blower motor retaining screws. 7. Lower blower motor assembly from unit housing. INSTALLATION For installation, reverse the above procedures. Then tape silencer into position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > With A/C > Page 5366 Blower Motor: Service and Repair Without A/C REMOVAL 1. Disconnect blower motor wiring connector. Blower Motor Removal 2. Grasp the blower motor while pulling down tab. Turn approximately 1/8 turn counterclockwise and remove blower motor assembly from unit housing. INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Resistor Block The blower motor resistor is located in the cowl, at the base of the windshield. There are two different resistor blocks depending on whether the vehicle is equipped with A/C or not. WARNING: The blower motor resistors will get hot when in use. Do not touch resistor block if the blower motor has been running. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 5370 Blower Motor Resistor: Service and Repair CAUTION: Blower motor resistor block can be very hot, use caution when working on or near it. Do not operate the blower motor with the resistor block removed. REMOVAL 1. Remove windshield wipers. 2. Remove cowl top screen. 3. Disconnect the resistor block wiring connector. 4. Remove two resistor block retaining screws. The screw threads attaching the resistor block are not full length. It is necessary to gently pry out the resistor block while turning the screws counterclockwise enabling the threads to engages. 5. Remove resistor block from vehicle. INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Testing and Inspection Blower Motor Switch: Testing and Inspection Heater A/C Blower Switch Test 1. Remove Heater A/C control module. Blower Switch Test 2. Use a ohmmeter, and check continuity between the terminals of the switch as shown in the Blower Switch Test. 3. If the switch fails any part of the continuity test, other then Pin 1 to Pin 7, replace Heater A/C Control. If no continuity between Pin 1 to Pin 7 check the lamps, replace if necessary. Heater Blower Switch Test 1. Remove heater control. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Testing and Inspection > Page 5374 Heater Blower Switch Test 2. Use a ohmmeter, and check continuity between the terminals of the switch as shown in the Heater Blower Test. 3. If switch fails any part of the continuity test, other then Pin 1 to Pin 7, replace heater control. If no continuity between Pin 1 to Pin 7 check the lamps, replace if necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Testing and Inspection > Page 5375 Blower Motor Switch: Service and Repair The switch is not serviced, replace heater A/C control. Refer to Heating and Air Conditioning/Control Assembly/service and Repair. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Clutch Air Gap ..................................................................................................................................... ............................ 0.35 - 0.65 mm (0.014 - 0.026 in.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Description and Operation > A/C Clutch Relay Operation Compressor Clutch: Description and Operation A/C Clutch Relay Operation Theory of Operation: The A/C compressor clutch relay controls the 12 volt source for the A/C clutch. The relay is located in the power distribution center. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the run position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). When A/C is requested, the PCM adjusts the idle speed to accommodate the A/C compressor load on the engine. The PCM grounds the relay control circuit after the PCM receives an A/C request and adjustment of the idle speed has been implemented. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Description and Operation > A/C Clutch Relay Operation > Page 5382 Compressor Clutch: Description and Operation Related Trouble Codes and Set Conditions Name of Code: A/C Clutch Relay Circuit When Monitored: With the ignition key in the run position and battery voltage above 10 volts. Set Condition: An open or shorted condition is detected in the A/C clutch relay control circuit. Theory of Operation: The A/C compressor clutch relay controls the 12 volt source for the A/C clutch. The relay is located in the power distribution center. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the run position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). When A/C is requested, the PCM adjusts the idle speed to accommodate the A/C compressor load on the engine. The PCM grounds the relay control circuit after the PCM receives an A/C request and adjustment of the idle speed has been implemented. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - Compressor clutch relay control circuit open or shorted - Inoperative circuit driver in powertrain control module Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Description and Operation > Page 5383 Compressor Clutch: Service and Repair REMOVAL NOTE: Compressor assembly must be removed from mounting. Although, refrigerant discharge is not necessary. Compressor Shaft Bolt And Clutch Plate 1. Remove the compressor shaft bolt. A band type oil filter removal tool can be placed around the clutch plate to aid in bolt removal. Clutch Plate And Shims 2. Tap the clutch plate with a plastic hammer and remove clutch plate and shim(s). CAUTION: Do not use screwdrivers between the clutch plate assembly and pulley to remove front plate as this may damage the front plate assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Description and Operation > Page 5384 Removing Pulley Snap Ring 3. Remove pulley retaining snap ring with Snap Ring Pliers (C-4574), and slide pulley assembly off of compressor. 4. Remove coil wire bracket/ground clip screw and wire harness. Clutch Coil Snap Ring 5. Remove snap ring retaining field coil onto compressor housing. Slide field coil off of compressor housing. 6. Examine frictional faces of the clutch pulley and front plate for wear. The pulley and front plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft nose area of the compressor for oil and remove the felt from the front cover. If the compressor felt is saturated with oil, the shaft seal is leaking and will have to be replaced. 7. Check bearing for roughness or excessive leakage of grease. Replace bearing as required. INSTALLATION 1. Align pin in back of field coil with hole in compressor end housing, and position field coil into place. Make sure that lead wires are properly routed, and fasten the diode and coil wire bracket with retaining screw. 2. Install field coil retaining snap ring with Snap Ring Pliers (C- 4574). Press snap ring to make sure it is properly seated in the groove. NOTE: The bevel side of the snap ring must be outward. Also both eyelets must be to the right or left of the pin on the compressor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Description and Operation > Page 5385 CAUTION: If snap ring is not fully seated it will vibrate out, resulting in a clutch failure and severe damage to the front face of the compressor. CAUTION: Do not mar the pulley frictional surface. Installing Pulley Assembly 3. Install pulley assembly to compressor. If necessary, tap gently with a block of wood on the friction surface. 4. Install pulley assembly retaining snap ring (bevel side outward) with Snap Ring Pliers (C-4574). Press the snap ring to make sure it is properly seated in the groove. NOTE: The bevel side of the snap ring must be facing outward. 5. If the original front plate assembly and pulley assembly are to be reused, the old shim(s) can be used. If not, place a trial stack of shims, 2.54 mm (0.10 in.) thick, on the shaft against the shoulder. 6. Install front plate assembly onto shaft. 7. If installing a new front plate and/or pulley assembly, the gap between front plate and pulley face must be checked. Use the following procedure: - Attach a dial indicator to front plate so that movement of the plate can be measured. - With the dial indicator zeroed on the front plate, energize the clutch and record the amount of movement. - The readings should be 0.35 to 0.65 mm (0.014 to 0.026 in.). If proper reading is not obtained, add or subtract shims until desired reading is obtained. 8. Install compressor shaft bolt. Tighten to 15.5 to 19.5 N.m (135 to 175 in. lbs.). NOTE: Shims may compress after tightening shaft nut. Check air gap in four or more places to verify if air gap is still correct. Spin pulley for final check. CLUTCH BREAK-IN After new clutch installation, cycle the A/C clutch 20 times (5 seconds ON and 5 seconds OFF). During this procedure, set the system to the A/C mode, engine rpm at 1500-2000, and high blower speed. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher clutch torque capability. NOTE: Excessive clutch gap will result in clutch slippage or non-engagement. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair Compressor Clutch Coil: Service and Repair REMOVAL NOTE: Compressor assembly must be removed from mounting. Although, refrigerant discharge is not necessary. Compressor Shaft Bolt And Clutch Plate 1. Remove the compressor shaft bolt. A band type oil filter removal tool can be placed around the clutch plate to aid in bolt removal. Clutch Plate And Shims 2. Tap the clutch plate with a plastic hammer and remove clutch plate and shim(s). CAUTION: Do not use screwdrivers between the clutch plate assembly and pulley to remove front plate as this may damage the front plate assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 5389 Removing Pulley Snap Ring 3. Remove pulley retaining snap ring with Snap Ring Pliers (C-4574), and slide pulley assembly off of compressor. 4. Remove coil wire bracket/ground clip screw and wire harness. Clutch Coil Snap Ring 5. Remove snap ring retaining field coil onto compressor housing. Slide field coil off of compressor housing. 6. Examine frictional faces of the clutch pulley and front plate for wear. The pulley and front plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft nose area of the compressor for oil and remove the felt from the front cover. If the compressor felt is saturated with oil, the shaft seal is leaking and will have to be replaced. 7. Check bearing for roughness or excessive leakage of grease. Replace bearing as required. INSTALLATION 1. Align pin in back of field coil with hole in compressor end housing, and position field coil into place. Make sure that lead wires are properly routed, and fasten the diode and coil wire bracket with retaining screw. 2. Install field coil retaining snap ring with Snap Ring Pliers (C- 4574). Press snap ring to make sure it is properly seated in the groove. NOTE: The bevel side of the snap ring must be outward. Also both eyelets must be to the right or left of the pin on the compressor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 5390 CAUTION: If snap ring is not fully seated it will vibrate out, resulting in a clutch failure and severe damage to the front face of the compressor. CAUTION: Do not mar the pulley frictional surface. Installing Pulley Assembly 3. Install pulley assembly to compressor. If necessary, tap gently with a block of wood on the friction surface. 4. Install pulley assembly retaining snap ring (bevel side outward) with Snap Ring Pliers (C-4574). Press the snap ring to make sure it is properly seated in the groove. NOTE: The bevel side of the snap ring must be facing outward. 5. If the original front plate assembly and pulley assembly are to be reused, the old shim(s) can be used. If not, place a trial stack of shims, 2.54 mm (0.10 in.) thick, on the shaft against the shoulder. 6. Install front plate assembly onto shaft. 7. If installing a new front plate and/or pulley assembly, the gap between front plate and pulley face must be checked. Use the following procedure: - Attach a dial indicator to front plate so that movement of the plate can be measured. - With the dial indicator zeroed on the front plate, energize the clutch and record the amount of movement. - The readings should be 0.35 to 0.65 mm (0.014 to 0.026 in.). If proper reading is not obtained, add or subtract shims until desired reading is obtained. 8. Install compressor shaft bolt. Tighten to 15.5 to 19.5 N.m (135 to 175 in. lbs.). NOTE: Shims may compress after tightening shaft nut. Check air gap in four or more places to verify if air gap is still correct. Spin pulley for final check. CLUTCH BREAK-IN After new clutch installation, cycle the A/C clutch 20 times (5 seconds ON and 5 seconds OFF). During this procedure, set the system to the A/C mode, engine rpm at 1500-2000, and high blower speed. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher clutch torque capability. NOTE: Excessive clutch gap will result in clutch slippage or non-engagement. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair Compressor Shaft Seal: Service and Repair COMPRESSOR FRONT SHAFT SEAL The compressor front shaft seal is not serviceable. If a leak is detected at the shaft seal, the compressor must be replaced as a unit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Power Distribution Center (Top) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair Condenser HVAC: Service and Repair The condenser is located in front of the engine radiator. It has no serviceable parts. If damaged or leaking, the condenser assembly must be replaced. WARNING: THE REFRIGERANT MUST BE REMOVED FROM THE SYSTEM BEFORE REMOVING THE CONDENSER. REMOVAL 1. Using a R-134a refrigerant recovery machine, remove the refrigerant from the A/C system. 2. Remove battery support strut. 3. Remove refrigerant lines from condenser. 4. Remove upper radiator mounts. 5. Remove condenser to radiator mounting screws. 6. Tilt radiator back and remove condenser. INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Solid State Relay The relay is located on the left front inner frame just behind the radiator. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 5403 Condenser Fan Motor Relay: Description and Operation Radiator Fan Control Module -PCM Output The radiator fan runs when coolant temperature and A/C system pressure demand cooling. The radiator fan circuit contains a Pulse Width Module (PWM) this is shown on the wiring as the Solid State Fan Relay. A 5 volt signal is supplied to the PWM. The PCM provides a pulsed ground for the PWM. Depending upon the amount of pulse on time, the PWM puts out a proportional voltage to the fan motor at the lower speed. For instance, if the on time is 30 percent, then the voltage to the fan motor will be 3.6 volts. When engine coolant reaches approximately 99°C (210°F) the PCM grounds the PWM relay. When the PCM grounds the relay it operates at a 30% duty cycle and immediately ramps up to 100% duty cycle. The PCM de-energizes the PWM relay when coolant temperature drops to approximately 93°C (199°F). Also, when the air conditioning pressure switch closes, the PCM grounds the PWM. The air conditioning switch closes at 285 psi ± 10 psi. When air conditioning pressure drops approximately 40 psi, the pressure switch opens and the fan turns off. The PWM relay is located on the left front inner frame just behind the radiator. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Heater-A/C Control Lamp Replacement Control Assembly: Service and Repair Heater-A/C Control Lamp Replacement REMOVAL 1. Remove the Heater A/C Control. 2. Remove the two center knobs by pulling the knob rearward. 3. Replace the lamp. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Heater-A/C Control Lamp Replacement > Page 5408 Control Assembly: Service and Repair Heater-A/C Control Replacement REMOVAL 1. Remove the top cover and cluster bezel. 2. Reach in and disconnect the wiring connector(s) for the rear window defogger and/or fog lamp switch(s) as required. 3. Remove the six attaching screws across the forward portion of the trim panel. Then lift the flange forward to disengage the three locator pins. 4. Pull panel rearward disengaging the clips along the bottom. 5. Open the ash receiver. 6. Remove the center bezel. Heater A/C Control 7. Remove three attaching screws at corners of the control 8. Pull the control rearward and disconnect the wiring connector. 9. Using a screwdriver, disengage the cable attachment clips. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors Technical Service Bulletin # 24-11-97 Date: 970711 A/C Evaporator - Emits Odors NO: 24-11-97 GROUP: Heater & A/C DATE: Jul. 11, 1997 SUBJECT: A/C Evaporator Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 REV. A, DATED MAY 26, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1995 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-96084). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1992 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1998 (AB) Ram Van/Wagon 1992 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1992 - 1993 (AG) Daytona 1992 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1998 (AN) Dakota 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1998 (BR) Ram Pickup 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1998 (GS) Chrysler Voyager (International Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1995 - 1998 (PL) Neon 1997 - 1998 (TJ) Wrangler 1992 - 1998 (XJ) Cherokee 1994 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the evaporator core. During normal A/C system operation, condensation forms in and around the A/C evaporator. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: Operate the A/C system, if a musty odor is experienced, perform the Repair Procedure. PARTS REQUIRED: 1 O4897625AA Cleaner, Aerosol Evaporator POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-93 AA, AC, AG, AJ, AY, PL, TJ, XJ, ZJ 0.7 Hrs. AB, AN, AP, BR, GS, JA, JX, NS 0.6 Hrs. LH 1.5 Hrs. AS, ES 1.0 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 5417 Repair Procedure This bulletin involves inspecting for leaves or other foreign material in the evaporator and HVAC housing and applying Mopar aerosol evaporator cleaner. NOTE: FOLLOW ALL CAUTIONS AND WARNING SUPPLIED WITH THE AEROSOL EVAPORATOR CLEANER; KEEP OUT OF REACH OF CHILDREN; AVOID CONTACT WITH SKIN OR EYES; WEAR SKIN AND EYE PROTECTION, IF SKIN OR EYE CONTACT OCCURS, WASH SKIN OR FLUSH EYES WITH GENEROUS AMOUNTS OF WATER; AVOID BREATHING VAPORS. 1. Inspect the evaporator and HVAC housing for leaves or other foreign material that may be blocking the air flow through the evaporator. If the build up is excessive replacement of the evaporator may be required. 2. With the parking brake applied and the transmission in Park, start the engine and let idle. Put the temperature control to full hot, blower speed to HIGH, select the PANEL and RE-CIRCULATE modes. Open all windows about 13 mm (1/2 in.). Disable the A/C compressor clutch by disconnecting its wiring connector or the wiring connector to the A/C pressure switch. NOTE: THIS PROCEDURE HEATS THE EVAPORATOR AND CAUSES MOISTURE TO EVAPORATE FASTER. THE SLIGHTLY OPEN WINDOWS ALLOW MOISTURE TO ESCAPE THE VEHICLE WITHOUT LOOSING MUCH HEAT. SOMETIMES, YOU MAY SEE A "FOG" CLOUDING THE WINDOWS. AFTER THIS "FOG" HAS DISAPPEARED CONTINUE TO OPERATE THE HEATER FOR ANOTHER 5 MINUTES. IF THE "FOG" NEVER APPEARED, OPERATE THE HEATER FOR A MINIMUM OF 30 MINUTES. 3. Turn the ignition switch to the OFF position. 4. Gain access to the evaporator cavity to apply the evaporator cleaner by: AB, 1992-93 AN, GS, JA, JX, LH, NS and PL - Remove evaporator fin temperature sensor access grommet. DO NOT REMOVE THE PROBE FROM THE EVAPORATOR. BR, TJ, XJ, ZG, ZJ - Remove blower resistor. For the above vehicles, place a piece of heavy masking tape over the opening in the evaporator housing where the fin temperature sensor access grommet or blower resistor was removed, then punch a small hole for the evaporator cleaner tube to be inserted into. AA, AC, AG, AJ, AP, and AY - Remove the screw attaching the right side floor duct. Use an 1/8 in. drill bit to drill through the bottom of the screw hole, Figure 1. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 5418 1994-98 AN - Drill an 1/8 in. hole at the mid-point of the rounded corner created by the intersection of the vertical and horizontal surfaces of the HVAC housing, refer to Figure 2. Place tape around the drill bit to prevent the bit from entering the housing more a 1/4 in. AS, ES - Remove the lower right instrument panel. Remove the blower motor cover. Make a template as illustrated below and drill an 1/8 in. hole as shown in Figure 3. Be sure to angle drill as illustrated. Shake evaporator cleaner aerosol can well and insert the application tube in the access hole created in step 3. NOTE: THE APPLICATION TUBE HAS A BLACK MARK AND A RED MARK ON IT INDICATING HOW FAR THE TUBE SHOULD BE INSERTED INTO THE EVAPORATOR CAVITY. THE RED MARK IS FOR AA, AC, AG, AJ, AP, AND AY BODY VEHICLES. THE BLACK MARK IS FOR ALL OTHER VEHICLES. 5. Start the engine and let idle. Set the blower motor to HIGH. 6. Put on goggles and dust mask type breathing protection. 7. Spray the entire contents of the evaporator cleaner into the evaporator cavity. NOTE: A "FOG" MAY BE SEEN ENTERING THE PASSENGER COMPARTMENT WHILE THE EVAPORATOR CLEANER IS BEING SPRAYED. THE EVAPORATOR CLEANER WILL NOT STAIN OR HARM THE VEHICLE INTERIOR, BUT GOGGLES AND BREATHING PROTECTION MUST BE WORN DURING CLEANER APPLICATION. DO NOT BREATH VAPORS! 8. When the can is empty, turn the ignition switch to the OFF position and let the vehicle sit for 20 minutes. This time will allow the cleaner to flow over and coat the evaporator fins and case assembly. 9. Install whatever components that were removed to gain access for application of the cleaner. On AS, ES and 1994-1998 AN, seal the access hole drilled in step 3 NOTE: OWNERS OF NS/GS VEHICLES THAT OPERATE IN CONDITIONS WHERE THE AIR INLET TO THE HVAC HOUSING IS SUBJECT TO FOREIGN MATERIAL, DEBRIS OR OTHER AIRBORNE CONTAMINATES, MAY WANT TO CONSIDER HAVING A MOPAR ACCESSORY CABIN AIR FILTER KIT INSTALLED, P/N 82202509. USE THE INSTRUCTIONS PACKAGED WITH THE KIT TO INSTALL IT. 10. Open all of the vehicle windows about 13 mm (1/2 in.). Start the engine and let idle for a MINIMUM of 30 minutes with the temperature control to full hot, blower speed to HIGH, PANEL and RE-CIRCULATE modes selected. This will dry and cure the evaporator cleaner onto the evaporator coil. 11. Connect the wiring disconnected in step 2 to re-enable the A/C compressor clutch. 12. Verify proper A/C operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors Technical Service Bulletin # 24-11-97 Date: 970711 A/C Evaporator - Emits Odors NO: 24-11-97 GROUP: Heater & A/C DATE: Jul. 11, 1997 SUBJECT: A/C Evaporator Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 REV. A, DATED MAY 26, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1995 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-96084). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1992 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1998 (AB) Ram Van/Wagon 1992 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1992 - 1993 (AG) Daytona 1992 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1998 (AN) Dakota 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1998 (BR) Ram Pickup 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1998 (GS) Chrysler Voyager (International Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1995 - 1998 (PL) Neon 1997 - 1998 (TJ) Wrangler 1992 - 1998 (XJ) Cherokee 1994 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the evaporator core. During normal A/C system operation, condensation forms in and around the A/C evaporator. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: Operate the A/C system, if a musty odor is experienced, perform the Repair Procedure. PARTS REQUIRED: 1 O4897625AA Cleaner, Aerosol Evaporator POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-93 AA, AC, AG, AJ, AY, PL, TJ, XJ, ZJ 0.7 Hrs. AB, AN, AP, BR, GS, JA, JX, NS 0.6 Hrs. LH 1.5 Hrs. AS, ES 1.0 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 5424 Repair Procedure This bulletin involves inspecting for leaves or other foreign material in the evaporator and HVAC housing and applying Mopar aerosol evaporator cleaner. NOTE: FOLLOW ALL CAUTIONS AND WARNING SUPPLIED WITH THE AEROSOL EVAPORATOR CLEANER; KEEP OUT OF REACH OF CHILDREN; AVOID CONTACT WITH SKIN OR EYES; WEAR SKIN AND EYE PROTECTION, IF SKIN OR EYE CONTACT OCCURS, WASH SKIN OR FLUSH EYES WITH GENEROUS AMOUNTS OF WATER; AVOID BREATHING VAPORS. 1. Inspect the evaporator and HVAC housing for leaves or other foreign material that may be blocking the air flow through the evaporator. If the build up is excessive replacement of the evaporator may be required. 2. With the parking brake applied and the transmission in Park, start the engine and let idle. Put the temperature control to full hot, blower speed to HIGH, select the PANEL and RE-CIRCULATE modes. Open all windows about 13 mm (1/2 in.). Disable the A/C compressor clutch by disconnecting its wiring connector or the wiring connector to the A/C pressure switch. NOTE: THIS PROCEDURE HEATS THE EVAPORATOR AND CAUSES MOISTURE TO EVAPORATE FASTER. THE SLIGHTLY OPEN WINDOWS ALLOW MOISTURE TO ESCAPE THE VEHICLE WITHOUT LOOSING MUCH HEAT. SOMETIMES, YOU MAY SEE A "FOG" CLOUDING THE WINDOWS. AFTER THIS "FOG" HAS DISAPPEARED CONTINUE TO OPERATE THE HEATER FOR ANOTHER 5 MINUTES. IF THE "FOG" NEVER APPEARED, OPERATE THE HEATER FOR A MINIMUM OF 30 MINUTES. 3. Turn the ignition switch to the OFF position. 4. Gain access to the evaporator cavity to apply the evaporator cleaner by: AB, 1992-93 AN, GS, JA, JX, LH, NS and PL - Remove evaporator fin temperature sensor access grommet. DO NOT REMOVE THE PROBE FROM THE EVAPORATOR. BR, TJ, XJ, ZG, ZJ - Remove blower resistor. For the above vehicles, place a piece of heavy masking tape over the opening in the evaporator housing where the fin temperature sensor access grommet or blower resistor was removed, then punch a small hole for the evaporator cleaner tube to be inserted into. AA, AC, AG, AJ, AP, and AY - Remove the screw attaching the right side floor duct. Use an 1/8 in. drill bit to drill through the bottom of the screw hole, Figure 1. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 5425 1994-98 AN - Drill an 1/8 in. hole at the mid-point of the rounded corner created by the intersection of the vertical and horizontal surfaces of the HVAC housing, refer to Figure 2. Place tape around the drill bit to prevent the bit from entering the housing more a 1/4 in. AS, ES - Remove the lower right instrument panel. Remove the blower motor cover. Make a template as illustrated below and drill an 1/8 in. hole as shown in Figure 3. Be sure to angle drill as illustrated. Shake evaporator cleaner aerosol can well and insert the application tube in the access hole created in step 3. NOTE: THE APPLICATION TUBE HAS A BLACK MARK AND A RED MARK ON IT INDICATING HOW FAR THE TUBE SHOULD BE INSERTED INTO THE EVAPORATOR CAVITY. THE RED MARK IS FOR AA, AC, AG, AJ, AP, AND AY BODY VEHICLES. THE BLACK MARK IS FOR ALL OTHER VEHICLES. 5. Start the engine and let idle. Set the blower motor to HIGH. 6. Put on goggles and dust mask type breathing protection. 7. Spray the entire contents of the evaporator cleaner into the evaporator cavity. NOTE: A "FOG" MAY BE SEEN ENTERING THE PASSENGER COMPARTMENT WHILE THE EVAPORATOR CLEANER IS BEING SPRAYED. THE EVAPORATOR CLEANER WILL NOT STAIN OR HARM THE VEHICLE INTERIOR, BUT GOGGLES AND BREATHING PROTECTION MUST BE WORN DURING CLEANER APPLICATION. DO NOT BREATH VAPORS! 8. When the can is empty, turn the ignition switch to the OFF position and let the vehicle sit for 20 minutes. This time will allow the cleaner to flow over and coat the evaporator fins and case assembly. 9. Install whatever components that were removed to gain access for application of the cleaner. On AS, ES and 1994-1998 AN, seal the access hole drilled in step 3 NOTE: OWNERS OF NS/GS VEHICLES THAT OPERATE IN CONDITIONS WHERE THE AIR INLET TO THE HVAC HOUSING IS SUBJECT TO FOREIGN MATERIAL, DEBRIS OR OTHER AIRBORNE CONTAMINATES, MAY WANT TO CONSIDER HAVING A MOPAR ACCESSORY CABIN AIR FILTER KIT INSTALLED, P/N 82202509. USE THE INSTRUCTIONS PACKAGED WITH THE KIT TO INSTALL IT. 10. Open all of the vehicle windows about 13 mm (1/2 in.). Start the engine and let idle for a MINIMUM of 30 minutes with the temperature control to full hot, blower speed to HIGH, PANEL and RE-CIRCULATE modes selected. This will dry and cure the evaporator cleaner onto the evaporator coil. 11. Connect the wiring disconnected in step 2 to re-enable the A/C compressor clutch. 12. Verify proper A/C operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5434 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5435 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5436 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5437 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5438 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5439 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5440 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5441 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5442 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5443 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5444 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5445 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5451 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5452 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5453 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5454 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5455 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5456 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5457 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5458 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5459 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5460 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5461 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5462 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 241496 > Sep > 96 > A/C , Heater - Odors/Defroster Will Not Clear Glass Evaporator Core: All Technical Service Bulletins A/C , Heater - Odors/Defroster Will Not Clear Glass NO: 24-14-96 GROUP: Heater & A/C DATE: Sep. 27, 1996 SUBJECT: A/C Evaporator Odor And/Or Incomplete Defrost In "Recirc" Mode MODELS: 1995 - 1997 (PL) Neon 1995 - 1997 (JA) Stratus/Cirrus/Breeze 1996 - 1997 (JX) Sebring Convertible SYMPTOM/CONDITION: A temporary musty odor may be emitted from the A/C ducts and/or the defroster may not be able to completely clear all the glass, when the recirculation mode (Recirc) is used for extended periods of time. DISCUSSION: The vehicles listed above offer a separate rotary knob for independent control of the Fresh (outside air) / "Recirc" (inside air) function. The intent of the independent control of Recirc is: ^ To temporarily allow customers to eliminate dust or outside odors. ^ To get maximum cooldown performance by going into "Recirc" without having to change modes or temperature settings. Prior to January 1995, the A/C evaporator had a chromate coating for long term corrosion protection and a silicate coating to insure that condensate would run off the fins instead of getting in the airstream and coming out the panel outlets. Due to new regulations, a new non-chromate coating process was implemented in January 1995. Under some ambient conditions the new coating may cause the air passing over the evaporator to develop a temporary musty odor. When operated in the "Recirc mode the odor is more noticeable. Also, operating for extended periods in "Recirc" with the A/C off may create and intensify the musty odor. Running in "Recirc" for long periods of time in very cold weather may cause moisture from snow tracked into the car and moisture from the occupants breath to condense on the cold glass and in some cases the defroster may not clear all the glass. Even with the A/C running on mild wet days and running in "Recirc" some fog may remain on areas of the glass. NOTE: CHANGES IN THE 1997 NEON WILL NOT ALLOW THE FRESH/RECIRC DOOR TO STAY IN RECIRC WHEN THE DEFROST MODE IS SELECTED. It is important that the instructions given in the owners manual that recommend that the "Recirc" mode be used for no more than 30 minutes at a time be followed. Encourage customers to operate in Fresh as the normal condition and go to Recirc only for the temporary conditions given above. POLICY: Information only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 241496 > Sep > 96 > A/C , Heater - Odors/Defroster Will Not Clear Glass Evaporator Core: All Technical Service Bulletins A/C , Heater - Odors/Defroster Will Not Clear Glass NO: 24-14-96 GROUP: Heater & A/C DATE: Sep. 27, 1996 SUBJECT: A/C Evaporator Odor And/Or Incomplete Defrost In "Recirc" Mode MODELS: 1995 - 1997 (PL) Neon 1995 - 1997 (JA) Stratus/Cirrus/Breeze 1996 - 1997 (JX) Sebring Convertible SYMPTOM/CONDITION: A temporary musty odor may be emitted from the A/C ducts and/or the defroster may not be able to completely clear all the glass, when the recirculation mode (Recirc) is used for extended periods of time. DISCUSSION: The vehicles listed above offer a separate rotary knob for independent control of the Fresh (outside air) / "Recirc" (inside air) function. The intent of the independent control of Recirc is: ^ To temporarily allow customers to eliminate dust or outside odors. ^ To get maximum cooldown performance by going into "Recirc" without having to change modes or temperature settings. Prior to January 1995, the A/C evaporator had a chromate coating for long term corrosion protection and a silicate coating to insure that condensate would run off the fins instead of getting in the airstream and coming out the panel outlets. Due to new regulations, a new non-chromate coating process was implemented in January 1995. Under some ambient conditions the new coating may cause the air passing over the evaporator to develop a temporary musty odor. When operated in the "Recirc mode the odor is more noticeable. Also, operating for extended periods in "Recirc" with the A/C off may create and intensify the musty odor. Running in "Recirc" for long periods of time in very cold weather may cause moisture from snow tracked into the car and moisture from the occupants breath to condense on the cold glass and in some cases the defroster may not clear all the glass. Even with the A/C running on mild wet days and running in "Recirc" some fog may remain on areas of the glass. NOTE: CHANGES IN THE 1997 NEON WILL NOT ALLOW THE FRESH/RECIRC DOOR TO STAY IN RECIRC WHEN THE DEFROST MODE IS SELECTED. It is important that the instructions given in the owners manual that recommend that the "Recirc" mode be used for no more than 30 minutes at a time be followed. Encourage customers to operate in Fresh as the normal condition and go to Recirc only for the temporary conditions given above. POLICY: Information only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5472 Evaporator Core: Service and Repair This vehicle uses an aluminum plate and fin style evaporator. It is located in the Evaporator/Blower module. The unit housing must be removed from the vehicle before beginning with this procedure. Refer to: "Housing Assembly HVAC : Service and Repair" See: Housing Assembly HVAC/Service and Repair Use this procedure if any or all of the following items require service: - Evaporator - Air inlet duct - Recirculation door - Evaporator/Blower module case DISASSEMBLE 1. Remove the clips and screws that hold the Unit Housing to the Evaporator/Blower Module. Then separate the two units. Foam Seat Removal 2. Remove the evaporator to dash panel foam seal. 3. Disconnect fin sensing switch from harness. 4. Remove upper to lower case retaining clips and screws. Case Separation 5. Separate the case halves. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5473 Evaporator Removal 6. Lift the evaporator out of the module. ASSEMBLE To reassemble, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 241896 > Nov > 96 > Evaporator Drain - Water Leaks Into Interior Evaporator Drain Tube: Customer Interest Evaporator Drain - Water Leaks Into Interior NO: 24-18-96 GROUP: Heating & A/C DATE: Nov. 22, 1996 SUBJECT: Water Leaks Into Passenger Compartment Under I/P By A/C Drain MODELS: 1996 - 1997 (PL) Neon SYMPTOM/CONDITION: Water leaks into passenger compartment from under the right side of the instrument panel. DIAGNOSIS: Raise the vehicle on a hoist to allow access to the A/C condensate drain tube. The condensate drain tube should be pointing down toward the ground. If the tube is pointing elsewhere or if there are signs of moisture up near the A/C evaporator nipple, perform the Repair Procedure. PARTS REQUIRED: 1 82300234 RTV Sealant REPAIR PROCEDURE: This bulletin involves the positioning of the A/C condensate drain tube and sealing between the drain tube and A/C evaporator drain nipple. 1. Remove the drain tube from the NC evaporator nipple. Figure 1 2. Dry any moisture present and apply RTV (PIN 82300234) around the sealing diameter of the drain tube. 3. Install the drain tube onto the evaporator nipple. Insure the drain tube is pointing down toward the ground. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-03-93 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 241896 > Nov > 96 > Evaporator Drain Water Leaks Into Interior Evaporator Drain Tube: All Technical Service Bulletins Evaporator Drain - Water Leaks Into Interior NO: 24-18-96 GROUP: Heating & A/C DATE: Nov. 22, 1996 SUBJECT: Water Leaks Into Passenger Compartment Under I/P By A/C Drain MODELS: 1996 - 1997 (PL) Neon SYMPTOM/CONDITION: Water leaks into passenger compartment from under the right side of the instrument panel. DIAGNOSIS: Raise the vehicle on a hoist to allow access to the A/C condensate drain tube. The condensate drain tube should be pointing down toward the ground. If the tube is pointing elsewhere or if there are signs of moisture up near the A/C evaporator nipple, perform the Repair Procedure. PARTS REQUIRED: 1 82300234 RTV Sealant REPAIR PROCEDURE: This bulletin involves the positioning of the A/C condensate drain tube and sealing between the drain tube and A/C evaporator drain nipple. 1. Remove the drain tube from the NC evaporator nipple. Figure 1 2. Dry any moisture present and apply RTV (PIN 82300234) around the sealing diameter of the drain tube. 3. Install the drain tube onto the evaporator nipple. Insure the drain tube is pointing down toward the ground. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-03-93 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Locations Evaporator Temperature Sensor/Clutch Cycling Switch: Locations Evaporator Probe Location The evaporator probe is located in the Evaporator Case unit housing and placed in the evaporator fins. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions Evaporator Temperature Sensor/Clutch Cycling Switch: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5492 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5493 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5494 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5495 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5496 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5497 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5498 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5499 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5500 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5501 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5502 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5503 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5504 Evaporator Temperature Sensor/Clutch Cycling Switch: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5505 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5506 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 5507 Evaporator Temperature Sensor/Clutch Cycling Switch: Description and Operation EVAPORATOR PROBE The evaporator probe can be replaced without having to remove the unit housing from the vehicle. The evaporator probe is located in the unit housing and placed in the evaporator fins. the probe prevents evaporator freeze-up. This is done by cycling the compressor clutch OFF when evaporator temperature rises above freeze point. It cycles ON when the evaporator temperature rises above freeze point. The evaporator probe uses a thermistor probe in a capillary tube. The tube is inserted between the evaporator fins in the heater-A/C unit housing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 5508 Evaporator Temperature Sensor/Clutch Cycling Switch: Testing and Inspection CAUTION: The work area and vehicle must be between 16° C (60° F) and 32° C (90° F) when testing the switch. 1. Disconnect the three wire connector from the evaporator probe lead located behind the glove box. 2. Start engine and set A/C to low blower motor speed, panel, full cool, and RECIRC. Evaporator Probe Harness Connector 3. Using a voltmeter, check for battery voltage between Pin 1 and 2. If no voltage is detected, there is no power to the switch. Check wiring and fuses. 4. Using a voltmeter, check for battery voltage between Pin 1 and Pin 3. If no voltage is detected, there is no voltage from the Powertrain Control Module. If voltage is OK, connect a jumper wire between Pin 1 and Pin 3. The compressor clutch should engage. If the clutch engages, remove the jumper wire immediately and go to Step 5. If the compressor clutch does not engage, check the operation of the clutch and repair as necessary. 5. If compressor clutch engages, connect the evaporator probe 3-way connector. The compressor clutch should engage or cycle depending on evaporator temperature. If OK, go to Step 6. If not OK, replace the clutch cycling switch. 6. The engine running and the A/C set to: - Blower motor on low speed - Panel position - Full cool - RECIRC. - Close all doors and windows. Place a thermometer in the center discharge vent. 7. If the clutch does not begin to cycle off between 2° C to 7° C (35° F to 45° F), verify that the evaporator probe is fully installed and not loose in evaporator. If it is not properly installed, install probe and reset outlet temperature. If the evaporator probe is properly installed, replace the clutch cycling switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 5509 Evaporator Temperature Sensor/Clutch Cycling Switch: Service and Repair REMOVAL NOTE: The evaporator probe can be replaced without having to remove the unit housing from the vehicle. 1. Disconnect probe wiring connector from behind the glove box. Evaporator Probe Location 2. Remove rubber grommet from evaporator blower module. 3. Note in which of the three pilot holes the evaporator probe is located. 4. Pull probe out of evaporator fins. INSTALLATION 1. There are three pilot holes available for the probe. The top hole is for service. If top hole was not used by previous probe, install probe in top hole. 2. If previous probe was removed from top hole, use a small plastic stick and make a new hole. Make the hole 1/4 inch above or below the original hole in the evaporator core. 3. Insert new probe into hole between evaporator fins. 4. Reinstall rubber grommet into evaporator probe access hole. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation Expansion Valve: Description and Operation The expansion valve is used to meter refrigerant into the evaporator in accordance with cooling requirements. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation > Page 5513 Expansion Valve: Testing and Inspection NOTE: Expansion valve tests should be performed after compressor tests. NOTE: Liquid CO2 is required to test the expansion valve. It is available from most welding supply facilities. CO2 is also available from companies which service and sell fire extinguishers. WARNING: Review Safety Precautions and Warnings Before proceding. CAUTION: The work area and vehicle must be 21 ° to 27 °C (70 ° to 85 °F) when testing expansion valve. TO TEST THE EXPANSION VALVE: 1. Connect a charging station or manifold gauge set to the refrigerant system service ports. Low Pressure Cut Off Switch 2. Disconnect wire connector at low pressure cutoff switch. Using a jumper wire, jump terminals inside wire connector boot. 3. Close all doors, windows and vents to the passenger compartment. 4. Set Heater-A/C control to A/C, full heat, floor, RECIRC. and high blower. 5. Start the engine and hold the idle speed (1000 rpm). After the engine has reached running temperature, allow the passenger compartment to heat up. This will create the need for maximum refrigerant flow into the evaporator. 6. If the refrigerant charge is sufficient, discharge (high pressure) gauge should read 965 to 2620 kPa (140 to 380 psi). Suction (low pressure) gauge should read 103 to 2417 kPa (15 to 35 psi). If system cannot achieve proper pressure readings, replace the expansion valve. If pressure is correct, proceed with test. WARNING: Protect skin and eyes from contacting CO2, personal injury can result. 7. If suction side low pressure is within specified range, freeze the expansion valve control head for 30 seconds. Use a super cold substance (liquid C02). Do not spray refrigerant on the expansion valve for this test. Suction side low pressure should drop to 34.5 kPa (5 psi) If not, replace expansion valve. 8. Allow expansion valve to thaw. The low pressure gauge reading should stabilize at 103 to 241 kPa (15 to 35 psi). If not, replace expansion valve. 9. When expansion valve test is complete, test A/C overall performance. Refer to Testing and Inspection/Performance Test. Remove all test equipment before returning vehicle to use. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation > Page 5514 Expansion Valve: Service and Repair WARNING: The refrigeration system must be completely empty before proceeding with this operation. REMOVAL 1. Remove the boot-type wire connector from the pressure cut-off switch. Expansion Valve 2. Remove the center bolt of refrigerant line plumbing sealing plate. 3. Carefully pull the refrigerant line-sealing plate assembly from the expansion valve towards front of vehicle. Do not scratch the expansion valve sealing surfaces with pilot tubes. 4. Cover the openings on A/C line-sealing plate assembly to prevent contamination. 5. Remove two screws securing the expansion valve to the evaporator sealing plate. 6. Carefully remove valve. INSTALLATION 1. Remove and replace the aluminum gasket on the evaporator sealing plate. 2. Carefully hold the expansion valve to the evaporator sealing plate so not to scratch the sealing surface. Install two screws and tighten to 8 to 14 N.m (70 to 130 in. lbs.). 3. Remove and replace the aluminum gasket on the refrigerant line- sealing plate assembly 4. Carefully hold the refrigerant line-sealing plate assembly to the expansion valve. Install bolt and tighten to 20 to 26 N.m (170 to 230 in. lbs.). 5. Connect wires to low pressure cut-off switch. 6. Evacuate and recharge system. 7. After expansion valve is installed, system is charged, and leaks have been checked, repeat A/C performance check. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair Heater Hose: Service and Repair CAUTION: When removing hoses from heater core inlet or outlet nipples DO NOT exert excess pressure. The heater core may become damaged and leak engine coolant. NOTE: Review Cooling System Precautions before proceeding with this operation. REMOVAL 1. Drain engine cooling system. 2. Remove clamp at end of heater hose to be removed. Heater Hose Quick Connect 3. ON Right Hand Drive (RHD) vehicles, heater hoses at the heater core connection have quick connects. The quick connect consist of two pieces; a quick connect and insert. The quick connect is removed by compressing the insert with a pliers, and pulling the quick connect free of the insert/nipple. Carefully compressed insert pulling the quick connect from connector nipple. The insert will remain on the connector nipple as the quick connect is removed. 4. Remove the heater hose clamp from the heater hose at the block and remove hose. INSTALLATION NOTE: The insert should be removed from the connector nipple and placed inside of the quick connect before reassembly. For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Locations High Pressure Safety Valve HVAC: Locations High Pressure Relief Valve The High Pressure Safety Valve is located on the compressor manifold. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Locations > Page 5521 High Pressure Safety Valve HVAC: Service and Repair WARNING: Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved service equipment meeting sae requirements to discharge R-134a system. If accidental system discharge occurs, ventilate work area before resuming service. R-134a service equipment or vehicle A/C system should not be pressure tested or leak tested with compressed air. Mixtures of air and R-134a can be combustible at elevated pressures. These mixtures are potentially dangerous and may result in fire or explosion causing injury or property damage. REMOVAL 1. Using a R-134a refrigerant recovery machine, remove the refrigerant from A/C system. High Pressure Relief Valve 2. Rotate the high pressure relief valve counterclockwise and separate relief valve from the vehicle. INSTALLATION For installation, reverse the above procedures using a new 0-ring seal. Evacuate and charge the refrigerant system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation Hose/Line HVAC: Description and Operation DISCHARGE LINE Discharge Line The discharge line is the line that goes from the compressor to the condenser. It has no serviceable parts except the rubber 0-rings. If the line is found to be leaking or is damaged it must be replaced as an assembly. LIQUID LINE Liquid/Suction Line The liquid line is the line that goes from the condenser to the drier. It has no serviceable parts except the rubber 0-rings. If the line is found to be leaking or is damaged it must be replaced as an assembly. SUCTION LINE The suction line is the large line that connects to the expansion valve and goes to the compressor. It also has a small line that goes to the filter/ drier. The suction line uses a gasket on the expansion valve side and rubber 0-rings on all other connections. There are no serviceable parts on the suction line other than the rubber 0-rings and expansion valve gasket. If the line is found to be leaking or is damaged it must be replaced as an assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Page 5525 Hose/Line HVAC: Service and Repair HANDLING TUBING AND FITTINGS Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and moisture can enter the system when it is opened for repair or replacement of lines or components. The refrigerant oil will absorb moisture readily out of the air. This moisture will convert to acids within a closed system. CAUTION: The system must be completely empty before opening any fitting or connection on the refrigerant system. Open fittings with caution even after system has been emptied. If pressure is noticed as a fitting is loosened, tighten fitting and evacuate system again. BENDING FLEX HOSE A good rule for the flexable hose lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharper bends will reduce the flow of the refrigerant. The flexible hose lines should be routed at least 3 inches away from exhaust manifolds. Inspect all flexible hose lines to make sure they are in good condition and properly routed. CAUTION: The use of correct wrenches when making connections is very important. Improper wrenches or the improper use of wrenches can damage the fittings. INTERNAL DAMAGE The internal parts of the A/C system will remain stable as long as moisture free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture, or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. OPENING SYSTEM When it is necessary to open the refrigeration system, have everything needed to service the system ready. The system should not be left open any longer than necessary. Cap or Plug all lines and fittings as soon as they are opened. This will prevent the entrance of dirt and moisture into the system. All new lines and components should be capped or sealed until they are ready to be used. CAUTION: All tools, including the refrigerant dispensing manifold, the manifold gauge set, and test hoses should be kept dry. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly Housing Assembly HVAC: Service and Repair Evaporator Housing Disassembly and Assembly Use this procedure if any or all of the following items require service: - Heater core - Temperature door - Mode door - Heat/Defrost door - Assembly housing The unit housing must be removed from the vehicle before beginning with this procedure. DISASSEMBLE For Right Hand Drive (RHD) vehicles, the Unit Housing does not separate. It is a one piece unit and must be replaced as a whole. Air Distribution Module Separation 1. Remove the clips and screws that hold the Air Distribution Module to the Evaporator/Blower Module. Then separate the two units. 2. Remove the panel opening foam seal, demister opening foam seal, and heater core tube foam seals from unit. Retaining Clip Removal 3. Remove the retaining clips and screws that hold the upper and lower housings together. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5530 Case Separation 4. Place the unit in the upside down position. Then separate the two halves of the module. Heater Core Removal 5. Lift the heater core out of the case. Temperature Door Removal 6. Press tab in at base of temperature door and release door from lever. Then remove the door. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5531 Mode Door Removal 7. Press tab in at base of mode door and release door from lever. Cam Screw Removal 8. Remove Heat/Defrost door cam screw. Cam And Lever Removal 9. Lift the cam and mode door lever off of the housing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5532 Pivot Screw Removal 10. Remove the Heat/Defrost link pivot screw. 11. Lift the Heat/Defrost link and the door as an assembly. Then separate the link from the door. ASSEMBLE To reassemble, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5533 Housing Assembly HVAC: Service and Repair Heater - A/C Housing Removal and Installation The instrument panel must be removed in order to remove the Unit Housing. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair WARNING: THE R-134a REFRIGERANT SYSTEM MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEM. REMOVAL 1. Remove instrument panel from vehicle. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair. 2. Drain cooling system and remove heater hoses at the dash panel. Place plugs in the heater core outlets to prevent coolant spillage during unit housing removal. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 3. Using a refrigerant recovery machine, remove the refrigerant from the A/C system, if equipped. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair 4. Remove suction line at expansion valve. Place a piece of tape over open refrigerant line to prevent moisture and/or dirt from entering the line. 5. Remove expansion valve from evaporator. Place a piece of tape over open evaporator fitting to prevent moisture and/or dirt from entering the evaporator. 6. Remove rubber drain tube extension from condensation drain tube. Dash Panel Studs 7. Remove three retaining nuts located in the engine compartment, on the dash panel. Retaining Screws 8. Remove the right side retaining screw. 9. Remove remaining nut located on dash panel stud. 10. Disconnect the blue five way connector from the plenum. Module wiring harness must be removed with module. 11. Remove assembly from the vehicle. For HVAC Unit Housing Disassembly and Assembly, refer to: "Evaporator Core : Service and Repair" See: Evaporator Core/Service and Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5534 INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair Receiver Dryer: Service and Repair The filter/drier is mounted in a rubber grommet on the right side of the engine compartment. The refrigerant must be recovered from the A/C system before replacing the filter/drier assembly. WARNING: The refrigeration system must be completely recovered before proceeding with this operation. REMOVAL 1. Disconnect liquid line from filter/drier. 2. Disconnect liquid line on suction line assembly from filter/drier. 3. Pull filter/drier out of rubber grommet. INSTALLATION For installation reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R134a Capacity ................................................................................................................................... ........................................ 0.78 kg (28 oz. or 1.57 lbs) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 5542 Refrigerant: Fluid Type Specifications Hydrofluorocarbon (HFC), ................................................................................................................... ............................................... R-134a liquefied gas Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Total System ........................................................................................................................................ ........................................................... 200 ml 6.75 oz. Condenser ........................................................................................................................................... ................................................................ 30 ml 1.0 oz. Evaporator ........................................................................................................................................... ............................................................... 59 ml 2.0 oz. Filter-Drier ...................................................... ................................................................................................................................................... 30 ml 1.0 oz. A/C Lines ............................................................................................................................................. .............................................................. 44 ml 1.5 oz. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 5547 Refrigerant Oil: Fluid Type Specifications Synthetic-based, Polyalkylene Glycol .................................................................................................. .......................................................................... ND-8 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 5548 Refrigerant Oil: Service and Repair It is important to have the correct amount of oil in the A/C system to ensure proper lubrication of the compressor. Too little oil will result in damage to the compressor. Too much oil will reduce the cooling capacity of the system and consequently result in higher discharge air temperatures. NOTE: The oil used in the compressor is ND8 PAG R-134a refrigerant oil. Only refrigerant oil of the same type should be used to service the system. Do not use any other oil. The oil container should be kept tightly capped until it is ready for use. Tightly cap afterwards to prevent contamination from dirt and moisture. Refrigerant oil will quickly absorb any moisture it comes in contact with. Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. It will not be necessary to check oil level in the compressor or to add oil unless there has been an oil loss. Oil loss at a leak point will be evident by the presence of a wet, shiny surface around the leak. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations High Pressure Cut Out Switch The high pressure cut out switch is located in the compressor manifold. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5553 High Pressure Sensor / Switch: Description and Operation HIGH PRESSURE CUT-OFF SWITCH The High Pressure Cut-Off Switch turns off the compressor if the system pressure exceeds 3240 kPa (470 psi). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5554 High Pressure Sensor / Switch: Service and Repair WARNING: The refrigerant must be removed from the system before removing the high pressure cut out switch. REMOVAL High Pressure Relief Valve 1. Disconnect wiring connector at the switch. 2. Remove internal snap ring. 3. Pull switch out of manifold. INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Low Pressure Sensor / Switch: Locations Low Pressure Cut Off Switch The low pressure cut off switch is located on the expansion valve. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5558 Low Pressure Sensor / Switch: Description and Operation DESCRIPTION The Low Pressure Cut Off Switch monitors the refrigerant gas pressure on the suction side of the system. OPERATION It turns off voltage to the compressor clutch coil when refrigerant gas pressure drops to levels that could damage the compressor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5559 Low Pressure Sensor / Switch: Testing and Inspection CAUTION: The work area must not be below 21°C (70°F) to test the compressor clutch circuit. 1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Raise hood and disconnect low pressure cut off switch connector boot. 3. Using a suitable jumper wire, jump across the terminals inside wire connector boot. 4. If the compressor clutch does not engage, the cycling clutch switch, wiring, relay, or fuse can be defective. 5. If clutch engages, connect manifold gauge set. Read low pressure gauge. At pressure above 97 kPa (14 psi) and above, low pressure out off switch will complete the clutch circuit. If the low pressure gauge reads below 140 kPa (20 psi), the system is low on refrigerant charge or empty due to a leak. 6. Install connector boot on switch and repeat Step 3. If the clutch does not engage, replace the low pressure cut off switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5560 Low Pressure Sensor / Switch: Service and Repair The low pressure cut out switch is a sealed factory calibrated unit. It must be replaced if defective. WARNING: The refrigeration system must be completely recovered before proceeding with this operation. REMOVAL 1. Disconnect the boot like wire connector at the cut off switch. Low Pressure Cut Off Switch 2. Using a sender unit removal socket, remove the switch from the expansion valve. INSTALLATION NOTE: Verity the 0-ring condition on the replacement switch. For installation, reverse the above procedures. Evacuate and charge the system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Power Distribution Center (Top) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Solid State Relay The relay is located on the left front inner frame just behind the radiator. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 5568 Condenser Fan Motor Relay: Description and Operation Radiator Fan Control Module -PCM Output The radiator fan runs when coolant temperature and A/C system pressure demand cooling. The radiator fan circuit contains a Pulse Width Module (PWM) this is shown on the wiring as the Solid State Fan Relay. A 5 volt signal is supplied to the PWM. The PCM provides a pulsed ground for the PWM. Depending upon the amount of pulse on time, the PWM puts out a proportional voltage to the fan motor at the lower speed. For instance, if the on time is 30 percent, then the voltage to the fan motor will be 3.6 volts. When engine coolant reaches approximately 99°C (210°F) the PCM grounds the PWM relay. When the PCM grounds the relay it operates at a 30% duty cycle and immediately ramps up to 100% duty cycle. The PCM de-energizes the PWM relay when coolant temperature drops to approximately 93°C (199°F). Also, when the air conditioning pressure switch closes, the PCM grounds the PWM. The air conditioning switch closes at 285 psi ± 10 psi. When air conditioning pressure drops approximately 40 psi, the pressure switch opens and the fan turns off. The PWM relay is located on the left front inner frame just behind the radiator. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection Blower Motor Switch: Testing and Inspection Heater A/C Blower Switch Test 1. Remove Heater A/C control module. Blower Switch Test 2. Use a ohmmeter, and check continuity between the terminals of the switch as shown in the Blower Switch Test. 3. If the switch fails any part of the continuity test, other then Pin 1 to Pin 7, replace Heater A/C Control. If no continuity between Pin 1 to Pin 7 check the lamps, replace if necessary. Heater Blower Switch Test 1. Remove heater control. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Page 5573 Heater Blower Switch Test 2. Use a ohmmeter, and check continuity between the terminals of the switch as shown in the Heater Blower Test. 3. If switch fails any part of the continuity test, other then Pin 1 to Pin 7, replace heater control. If no continuity between Pin 1 to Pin 7 check the lamps, replace if necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Page 5574 Blower Motor Switch: Service and Repair The switch is not serviced, replace heater A/C control. Refer to Heating and Air Conditioning/Control Assembly/service and Repair. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Locations Evaporator Temperature Sensor/Clutch Cycling Switch: Locations Evaporator Probe Location The evaporator probe is located in the Evaporator Case unit housing and placed in the evaporator fins. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions Evaporator Temperature Sensor/Clutch Cycling Switch: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5580 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5581 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5582 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5583 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5584 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5585 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5586 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5587 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5588 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5589 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5590 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5591 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5592 Evaporator Temperature Sensor/Clutch Cycling Switch: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5593 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5594 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 5595 Evaporator Temperature Sensor/Clutch Cycling Switch: Description and Operation EVAPORATOR PROBE The evaporator probe can be replaced without having to remove the unit housing from the vehicle. The evaporator probe is located in the unit housing and placed in the evaporator fins. the probe prevents evaporator freeze-up. This is done by cycling the compressor clutch OFF when evaporator temperature rises above freeze point. It cycles ON when the evaporator temperature rises above freeze point. The evaporator probe uses a thermistor probe in a capillary tube. The tube is inserted between the evaporator fins in the heater-A/C unit housing. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 5596 Evaporator Temperature Sensor/Clutch Cycling Switch: Testing and Inspection CAUTION: The work area and vehicle must be between 16° C (60° F) and 32° C (90° F) when testing the switch. 1. Disconnect the three wire connector from the evaporator probe lead located behind the glove box. 2. Start engine and set A/C to low blower motor speed, panel, full cool, and RECIRC. Evaporator Probe Harness Connector 3. Using a voltmeter, check for battery voltage between Pin 1 and 2. If no voltage is detected, there is no power to the switch. Check wiring and fuses. 4. Using a voltmeter, check for battery voltage between Pin 1 and Pin 3. If no voltage is detected, there is no voltage from the Powertrain Control Module. If voltage is OK, connect a jumper wire between Pin 1 and Pin 3. The compressor clutch should engage. If the clutch engages, remove the jumper wire immediately and go to Step 5. If the compressor clutch does not engage, check the operation of the clutch and repair as necessary. 5. If compressor clutch engages, connect the evaporator probe 3-way connector. The compressor clutch should engage or cycle depending on evaporator temperature. If OK, go to Step 6. If not OK, replace the clutch cycling switch. 6. The engine running and the A/C set to: - Blower motor on low speed - Panel position - Full cool - RECIRC. - Close all doors and windows. Place a thermometer in the center discharge vent. 7. If the clutch does not begin to cycle off between 2° C to 7° C (35° F to 45° F), verify that the evaporator probe is fully installed and not loose in evaporator. If it is not properly installed, install probe and reset outlet temperature. If the evaporator probe is properly installed, replace the clutch cycling switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 5597 Evaporator Temperature Sensor/Clutch Cycling Switch: Service and Repair REMOVAL NOTE: The evaporator probe can be replaced without having to remove the unit housing from the vehicle. 1. Disconnect probe wiring connector from behind the glove box. Evaporator Probe Location 2. Remove rubber grommet from evaporator blower module. 3. Note in which of the three pilot holes the evaporator probe is located. 4. Pull probe out of evaporator fins. INSTALLATION 1. There are three pilot holes available for the probe. The top hole is for service. If top hole was not used by previous probe, install probe in top hole. 2. If previous probe was removed from top hole, use a small plastic stick and make a new hole. Make the hole 1/4 inch above or below the original hole in the evaporator core. 3. Insert new probe into hole between evaporator fins. 4. Reinstall rubber grommet into evaporator probe access hole. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations High Pressure Cut Out Switch The high pressure cut out switch is located in the compressor manifold. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5602 High Pressure Sensor / Switch: Description and Operation HIGH PRESSURE CUT-OFF SWITCH The High Pressure Cut-Off Switch turns off the compressor if the system pressure exceeds 3240 kPa (470 psi). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5603 High Pressure Sensor / Switch: Service and Repair WARNING: The refrigerant must be removed from the system before removing the high pressure cut out switch. REMOVAL High Pressure Relief Valve 1. Disconnect wiring connector at the switch. 2. Remove internal snap ring. 3. Pull switch out of manifold. INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Low Pressure Sensor / Switch: Locations Low Pressure Cut Off Switch The low pressure cut off switch is located on the expansion valve. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5607 Low Pressure Sensor / Switch: Description and Operation DESCRIPTION The Low Pressure Cut Off Switch monitors the refrigerant gas pressure on the suction side of the system. OPERATION It turns off voltage to the compressor clutch coil when refrigerant gas pressure drops to levels that could damage the compressor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5608 Low Pressure Sensor / Switch: Testing and Inspection CAUTION: The work area must not be below 21°C (70°F) to test the compressor clutch circuit. 1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Raise hood and disconnect low pressure cut off switch connector boot. 3. Using a suitable jumper wire, jump across the terminals inside wire connector boot. 4. If the compressor clutch does not engage, the cycling clutch switch, wiring, relay, or fuse can be defective. 5. If clutch engages, connect manifold gauge set. Read low pressure gauge. At pressure above 97 kPa (14 psi) and above, low pressure out off switch will complete the clutch circuit. If the low pressure gauge reads below 140 kPa (20 psi), the system is low on refrigerant charge or empty due to a leak. 6. Install connector boot on switch and repeat Step 3. If the clutch does not engage, replace the low pressure cut off switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5609 Low Pressure Sensor / Switch: Service and Repair The low pressure cut out switch is a sealed factory calibrated unit. It must be replaced if defective. WARNING: The refrigeration system must be completely recovered before proceeding with this operation. REMOVAL 1. Disconnect the boot like wire connector at the cut off switch. Low Pressure Cut Off Switch 2. Using a sender unit removal socket, remove the switch from the expansion valve. INSTALLATION NOTE: Verity the 0-ring condition on the replacement switch. For installation, reverse the above procedures. Evacuate and charge the system. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Service Port HVAC: Locations High Side Service Port The high side service port is located on the filter drier. Low Side Service Port Valve (in Suction Line) The low side service port is located on the suction line. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 5613 Service Port HVAC: Service and Repair REMOVAL High Side Service Port Low Side Service Port Valve (in Suction Line) 1. Remove the valve caps. 2. Using a R-134a refrigerant recovery machine, Remove the refrigerant from A/C system. 3. Using a standard valve core tool, remove the valve core. Be careful to prevent any dirt/debris from entering the valve core opening or getting on the replacement valve core. INSTALLATION 1. When assembling the new valve core into the port, the core should be oiled with clean ND8 PAG compressor oil. CAUTION: A valve that is not fully seated can lead to damage to the valve during evacuation and charge. This can result in system refrigerant discharge while uncoupling the charge adapters. 2. Install valve core into port. 3. Evacuate and charge the A/C system. 4. Install the valve caps. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components . Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 5620 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming 1. Verify that the negative battery cable is disconnected and isolated. 2. Connect scan tool (DRB) to Data Link connector, located at right side of the steering column and at the lower edge of the lower instrument panel. 3. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 4. After checking that no one is inside the vehicle, connect the battery negative terminal. 5. Using the scan tool, read and record active diagnostic code data. 6. Read and record any stored diagnostic codes. 7. Refer to the airbag system Diagnostic Test if any diagnostic codes are found in Step 5 or Step 6. 8. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the airbag system Diagnostic Test. If the airbag warning lamp either fails to light with the ignition switch ON, or the light goes on and stays on, there is a system malfunction. Refer to the airbag system Diagnostic Test. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > NHTSA97V080000 > May > 97 > Recall 97V080000: Unexpected Air Bag Deployment Air Bag: Recalls Recall 97V080000: Unexpected Air Bag Deployment The electrical circuit design allows the potential for an inadvertent air bag deployment upon vehicle ignition shut down. Unexpected air bag deployment can result in occupant injury. Dealers will replace the air bag electronic control module with a newly designed module. Owner notification began during July 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service Air Bag: All Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 5634 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > NHTSA97V080000 > May > 97 > Recall 97V080000: Unexpected Air Bag Deployment Air Bag: All Technical Service Bulletins Recall 97V080000: Unexpected Air Bag Deployment The electrical circuit design allows the potential for an inadvertent air bag deployment upon vehicle ignition shut down. Unexpected air bag deployment can result in occupant injury. Dealers will replace the air bag electronic control module with a newly designed module. Owner notification began during July 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service Air Bag: All Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 5644 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations Air Bag: Component Locations Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations > Page 5647 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Diagram Information and Instructions Air Bag: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Diagram Information and Instructions > Page 5650 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Diagram Information and Instructions > Page 5651 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Diagram Information and Instructions > Page 5652 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Diagram Information and Instructions > Page 5653 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Diagram Information and Instructions > Page 5654 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Diagram Information and Instructions > Page 5655 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Diagram Information and Instructions > Page 5656 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Diagram Information and Instructions > Page 5657 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Diagram Information and Instructions > Page 5658 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Diagram Information and Instructions > Page 5659 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Diagram Information and Instructions > Page 5660 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Diagram Information and Instructions > Page 5661 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Diagram Information and Instructions > Page 5662 Air Bag: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Diagram Information and Instructions > Page 5663 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Diagram Information and Instructions > Page 5664 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Diagram Information and Instructions > Page 5665 Air Bag: Connector Views Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Diagram Information and Instructions > Page 5666 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Diagram Information and Instructions > Page 5667 Air Bag: Electrical Diagrams Airbag System (Part 1 Of 3) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Diagram Information and Instructions > Page 5668 Airbag System (Part 2 Of 3) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Diagram Information and Instructions > Page 5669 Airbag System (Part 3 Of 3) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Page 5670 Air Bag: Testing and Inspection 1. Disconnect and isolate the negative battery cable. 2. Connect scan tool (DRB) to Data Link connector, located at right side of the steering column and at the lower edge of the lower instrument panel. 3. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 4. After checking that no one is inside the vehicle, connect the battery negative terminal. 5. Using the scan tool, read and record active diagnostic code data. 6. Read and record any stored diagnostic codes. 7. Refer to the airbag system Diagnostic Test if any diagnostic codes are found in Step 5 or Step 6. 8. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the airbag system Diagnostic Test. If the airbag warning lamp either fails to light with the ignition switch on, or the light goes on and stays on, there is a system malfunction. Refer to the airbag system Diagnostic Test. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Maintenance Inspection Air Bag: Service and Repair Maintenance Inspection 1. Check the airbag warning lamp for proper operation as follows: a. Turn ignition switch to the ON position, the airbag warning lamp should light. If not, test the system using a scan tool and airbag system Diagnostic Procedures. Repair as required. b. The airbag warning lamp lights, but fails to go out after 8 Seconds. Test the system using a scan tool and airbag system System Diagnostic Procedures. Repair as required. c. After correcting active malfunction erase stored diagnostic codes. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Maintenance Inspection > Page 5673 Air Bag: Service and Repair Airbag Module Storage & Handling Deployed Module The vehicle interior may contain a very small amount of sodium hydroxide powder, a by-product of airbag deployment. Sodium hydroxide powder can irritate the skin, eyes, nose and throat. Wear safety glasses, rubber gloves, and long sleeved clothing when cleaning any of the powder residue from the vehicle. If you find that the cleanup is irritating your skin, run cool water over the affected area. Also, if you experience nasal or throat irritation, exit the vehicle for fresh air until the irritation ceases. If irritation continues, see a physician. Undeployed The airbag module(s) must be stored in its original special container until used for service. At no time should a source of electricity be permitted near the inflator on the back of an airbag module. When carrying or handling an undeployed airbag module, the trim side of the airbag should be pointing away from the body to minimize possibility of injury if accidental deployment occurs. Do not place undeployed air-bag face down on a solid surface, the airbag will propel into the air if accidental deployment occurs. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Maintenance Inspection > Page 5674 Air Bag: Service and Repair Driver Side Airbag Module Replacement REMOVAL WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION PROCEDURE. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR 2 MINUTES BEFORE REMOVING ANY AIRBAG COMPONENTS. When removing a deployed module, rubber gloves, eye protection and long sleeved shift should be worn as there may be deposits on the surface which could irritate the skin and eyes. 1. Disconnect and isolate the battery negative cable. 2. Remove speed control switches or covers from steering wheel armature and disconnect the wires. Driver Airbag Module 3. Remove two bolts attaching Driver Airbag Module from the sides of steering wheel. 4. Lift module and disconnect airbag squib wire connector and horn wire. 5. Remove Driver Airbag Module. 6. When replacing a deployed driver airbag module, the clockspring must also be replaced. Refer to Clockspring Removal and Installation for proper procedure. INSTALLATION - For installation, reverse the above procedures. 1. Connect the squib wire to the module. Make airbag connection by pressing straight in on the connector. The connector should be fully seated feel for positive snap to assure positive connection. 2. Connect the horn wire. 3. Install two bolts and tighten to 10 to 11 N.m (90 to 100 in. lbs.) torque. 4. install non-speed control covers to the steering wheel armature or connect the wire connectors to the speed control switches and install switches. Tighten fastener to 2 N.m (20 in. lbs.). 5. Do not connect battery negative cable. Refer to Diagnosis and Testing for Airbag System Test procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Maintenance Inspection > Page 5675 Air Bag: Service and Repair Passenger Side Airbag Module Replacement Non-Deployed Module REMOVAL When removing a module for any reason other than DEPLOYMENT. 1. Disconnect and isolate the battery negative cable. Instrument Panel 2. Remove instrument panel top cover. 3. Remove instrument panel right trim bezel. 4. Open glove box and push the sides inward allowing the door bumper to pass and box to open. Passenger Airbag Module 5. Remove the four trim screws which attach the Passenger Airbag Module to the top instrument panel. 6. Remove two module attaching nuts from the support structure. Airbag Module Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Maintenance Inspection > Page 5676 7. Lift module up until the wire connector is visible and disconnect the 4-way wire connector from module. Unlock the red locking tab and compress lock to release the connector. INSTALLATION - For installation, reverse the above procedures. Ensure that the red locking tab is in the lock position after installing the connector. Tighten trim screws to 2 N.m (20 in. lbs.) torque. Tighten the module nuts to 22 to 34 N.m (200 to 300 in. lbs.) torque. Do not connect battery negative cable. Refer to Diagnosis and Testing for Airbag System Test procedures. Deployed Module REMOVAL When removing a deployed module, rubber gloves, eye protection, and a long-sleeved shirt should be worn, as there may be deposits on the surface which could irritate the skin and eyes. 1. Disconnect and isolate the battery negative cable. 2. Roll/fold airbag towards instrument panel. 3. Close door over folded airbag and tape door closed. 4. Remove instrument panel top cover. 5. Remove instrument panel right trim panel. 6. Open glove box and push the sides inward allowing the door bumper to pass and box to open. 7. Remove the four trim screws which attach the module to the top instrument panel. 8. Remove two module attaching nuts from the support structure. 9. Lift module up until the wire connector is visible and disconnect the 4-way wire connector from module. Unlock the red locking tab and compress lock to release the connector. INSTALLATION - For installation, reverse the above procedures. Ensure that the red locking tab is in the lock position after installing the connector. Tighten trim screws to 2 N.m (20 in lbs.) torque. Tighten the module nuts to 22 to 34 N.m (200 to 300 in lbs.) torque. Do not connect battery negative cable. Refer to Diagnosis and Testing for Airbag System Test procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Maintenance Inspection > Page 5677 Air Bag: Service and Repair Service of Deployed Airbag Module DRIVER AIRBAG After a Driver Airbag Module has been deployed the following components must be replaced because they cannot be reused. Other driver airbag system components are replaced if damaged. Driver Airbag Module - Clockspring assembly PASSENGER AIRBAG After a Passenger Airbag Module has been deployed the following components must be replaced because they cannot be reused. - Passenger Airbag Module - Right trim panel The lower instrument panel knee blocker, top cover, and any other components should be replaced if damaged. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module Technical Service Bulletin # 731 Date: 970701 Recall - Airbag Control Module No. 731 July, 1997 To: All Dealers Subject: Safety Recall # 731 -- Airbag Control Module Models: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. To correct this condition, the airbag control module (ACM) must be replaced. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for service as determined by using DIAL System Function 70. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53, 70 and VIP All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time of recall implementation for dealer inquiry as needed. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5686 Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough of each ACM Package to service about 25% of those vehicles. Each package contains one (1) ACM. Refer to the table above for the appropriate package application: Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Service Procedure For Neon (PL) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. For Manual Transmission Equipped Vehicles: Remove the shifter knob fastener and remove the shifter knob. 3. Remove the front two (2) center console attaching screws located near the cup holders (Figure 1). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5687 4. Remove the two (2) screws at the bottom of the storage bin (Figure 2). 5. Remove the bolt access covers and the two lower console bracket bolts on each side of the console bin. 6. Raise the park brake hand lever as high as possible. 7. Remove the center console assembly. WARNING: The auto adjusting feature of the park brake lever assembly contains a clock spring loaded to approximately 20 lbs. DO NOT release the auto adjuster lock out device before installing the cables into the equalizer. Keep hands out of auto adjuster sector and pawl area. Failure to observe caution in handling this mechanism could lead to serious injury. 8. Lower the park brake handle. 9. Grasp the park brake lever output cable by hand and pull upward until a 3/16" drill bit can be inserted into the handle and sector gear mechanism (Figure 3). This will remove the tension from the park brake cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5688 10. Remove both rear park brake cables from the park brake cable equalizer (Figure 4). 11. Disconnect the brake warning light electrical connector from the park brake lever switch. 12. Remove the two park brake lever attaching nuts and remove the park brake lever assembly. 13. Disconnect the ACM wiring connector (Figure 5): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 14. Remove the remaining three (3) nuts that secure the ACM mounting bracket to the floor, disconnect the two (2) park brake lever switch wire harness clips from the ACM bracket and then remove the ACM and bracket assembly. 15. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 16. Loosely install the three (3) ACM attaching nuts. 17. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5689 18. Install the park brake lever assembly. 19. Tighten the four (4) ACM nuts and the remaining park brake lever nut to 115 in-lbs (12.5 N.m). 20. Connect the park brake lever switch electrical connector and attach the wiring clips to the ACM bracket. 21. Install both rear park brake cables into the equalizer. 22. Pull the park brake lever handle all the way up. 23. Firmly grasp the park brake lever locking pin (drill bit) and quickly remove it from the mechanism. 24. Cycle the park brake lever once to position the park brake cables. 25. Make sure that the park brake lever is fully raised and then install the center console assembly. 26. Install the front two (2) center console attaching screws located near the cup holders (Figure 1). 27. Install the two (2) screws at the bottom of the storage bin (Figure 2). 28. Install the two (2) outer lower console bracket bolts on each side of the storage bin and then install the bolt covers. 29. For Manual Transmission Equipped Vehicles: Install the shifter knob and fastener. 30. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 31. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 32. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Dakota (AN) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area around the center instrument panel support. 3. Remove the two (2) front center support bracket screws (Figure 6). 4. Remove the two (2) left side and one (1) right side support bracket screws (Figure 6). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5690 5. Remove the support bracket. 6. Remove the ground eyelet screw from the left side of the ACM bracket. 7. Disconnect the ACM wiring connector (Figure 7): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 8. Remove the three (3) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 8). 9. Remove the ACM and bracket assembly. 10. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 11. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 105 in-lbs (11.8 N.m). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5691 12. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 13. Install the ground eyelet screw to the left side of the ACM bracket. 14. Install the center instrument panel support bracket. 15. Install the two (2) left side and one (1) right side support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 16. Install the two (2) front center support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 17. Reinstall the floor carpet around the center instrument panel support. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Wrangler (TJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area under the heater-A/C housing floor duct and forward of the center floor console. 3. For vehicles equipped with ABS: Remove the ABS acceleration sensor from its mounting bracket and set aside (Figure 9). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5692 4. Remove the four (4) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 10). 5. Disconnect the ACM wiring connector (Figure 11): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 6. Slide the ACM and bracket assembly out from under the heater-A/C housing floor duct and remove it from the vehicle. 7. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 8. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 9. Tighten the four (4) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m) (Figure 10). 10. For vehicles equipped with ABS: Reinstall the ABS acceleration sensor (Figure 9). Tighten the sensor mounting bolts to 40 in-lbs (4.5 N.m). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5693 11. Reinstall the floor carpet under the heater-A/C floor duct. 12. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 13. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 14. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Grand Cherokee (ZJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the transmission shift lever handle by pulling straight up firmly and quickly. 3. Pry up the transmission shift indicator bezel with a trim stick (Figure 12). 4. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transmission shift indicator bezel from the console. 5. Pry up the transfer case shift indicator bezel with a trim stick (Figure 12). 6. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transfer case bezel from the console. 7. Remove the console attaching screws and then remove the console (Figure 12). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5694 8. Disconnect the ACM wiring connector (Figure 13): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 9. Remove the four (4) screws that secure the ACM mounting bracket to the floor transmission tunnel (Figure 14). 10. Remove the ACM and bracket assembly. 11. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 12. Tighten the four (4) ACM attaching screws to 95 in-lbs (10.7 N.m). 13. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 14. Install the console and secure it with the attaching screws (Figure 12). 15. Install the lamp socket into the transfer case shift bezel and then install the bezel into the console (Figure 12). 16. Install the lamp socket into the transmission shift indicator bezel and then install the bezel into the console (Figure 12). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5695 17. Install the transmission shift lever handle. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Viper GTS Coupe (SR) Vehicles: 1. Remove the left rear wheel and tire assembly. 2. Remove the left rear wheel well inner splash shield. 3. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 4. Remove the instrument panel center bezel and then disconnect the rear window defogger switch, the power window switches and the lighter (Figure 15). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5696 5. Remove the right and left knee blockers (Figure 16). 6. Remove the headlamp switch knob by inserting a paper clip in the hole under the knob and pushing gently to release the lock clip (Figure 16). 7. Remove the tilt steering handle. 8. Remove the upper steering column shroud. 9. Remove the instrument panel bezel (Figure 16). NOTE: Be careful not to break the headlamp switch lock tab when removing the I/P bezel. 10. Remove the two (2) radio mounting screws. 11. Remove the radio and disconnect the wire connector, coaxial cable and antenna cable. 12. Remove the radio from the vehicle. 13. Remove the HVAC control module. Only disconnect the vacuum and electrical connectors. Do not disconnect the cable. Set the control module aside. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5697 14. Reach through the radio opening and disconnect the ACM wiring connector (Figure 17): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 15. Remove the three (3) nuts that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 18). 16. Slide the ACM and bracket assembly out through the radio opening. 17. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 18. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m). 19. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 20. Connect the HVAC control head electrical and vacuum connectors. Install the HVAC control module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5698 21. Connect the radio wire connector, coaxial cable and antenna cable. 22. Install the radio into the instrument panel and tighten the two (2) mounting screws. 23. Install the instrument panel bezel (Figure 16). NOTE: Be careful when installing the I/P bezel. Do not break the headlamp switch lock tab. 24. Install the headlamp switch knob (Figure 16). 25. Install the upper steering column cover. 26. Install the tilt steering handle. 27. Install the right and left knee blockers (Figure 16). 28. Connect the rear window defogger switch, the power window switches and the lighter and then install the instrument panel center bezel (Figure 15). 29. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 30. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 31. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. 32. Install the left rear wheel well inner splash shield. 33. Install the left rear wheel and tire assembly. Completion Reporting and Reimbursement / Parts Return Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. Parts Return Initially, a small number of ACM and bracket assemblies are required to be returned to the Warranty Material Return Center. When an adequate number of returned parts have been accumulated, Parts Return Documents will no longer be generated and parts are to be discarded. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5699 CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dealer Service Instructions IMPORTANT Safety Recall # 731 -- Airbag Control Module ^ Effective immediately, this recall (# 731) cancels and supercedes Recall # 683 -- Airbag Control Module for 1997 Jeep Wrangler (TJ) vehicles. ^ This service requirement applies only to: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) ^ The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position. To correct this condition, the airbag control module (ACM) must be replaced. Parts Packages: ^ Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough ACM Packages to service about 25% of those vehicles. Owner Letter SAFETY RECALL TO REPLACE YOUR VEHICLE'S AIRBAG CONTROL MODULE Dear Chrysler Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1997 Plymouth and Dodge Neon; Dodge Dakota; Jeep Grand Cherokee and Wrangler; and 1996 Dodge Viper GTS Coupe vehicles. The problem is... The airbags on your vehicle (identified on the enclosed form), may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. What Chrysler and your dealer will do... Chrysler will repair your (vehicle) free of charge (parts and labor). To do this, your dealer will replace the airbag control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5700 If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module Technical Service Bulletin # 731 Date: 970701 Recall - Airbag Control Module No. 731 July, 1997 To: All Dealers Subject: Safety Recall # 731 -- Airbag Control Module Models: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. To correct this condition, the airbag control module (ACM) must be replaced. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for service as determined by using DIAL System Function 70. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53, 70 and VIP All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time of recall implementation for dealer inquiry as needed. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5706 Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough of each ACM Package to service about 25% of those vehicles. Each package contains one (1) ACM. Refer to the table above for the appropriate package application: Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Service Procedure For Neon (PL) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. For Manual Transmission Equipped Vehicles: Remove the shifter knob fastener and remove the shifter knob. 3. Remove the front two (2) center console attaching screws located near the cup holders (Figure 1). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5707 4. Remove the two (2) screws at the bottom of the storage bin (Figure 2). 5. Remove the bolt access covers and the two lower console bracket bolts on each side of the console bin. 6. Raise the park brake hand lever as high as possible. 7. Remove the center console assembly. WARNING: The auto adjusting feature of the park brake lever assembly contains a clock spring loaded to approximately 20 lbs. DO NOT release the auto adjuster lock out device before installing the cables into the equalizer. Keep hands out of auto adjuster sector and pawl area. Failure to observe caution in handling this mechanism could lead to serious injury. 8. Lower the park brake handle. 9. Grasp the park brake lever output cable by hand and pull upward until a 3/16" drill bit can be inserted into the handle and sector gear mechanism (Figure 3). This will remove the tension from the park brake cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5708 10. Remove both rear park brake cables from the park brake cable equalizer (Figure 4). 11. Disconnect the brake warning light electrical connector from the park brake lever switch. 12. Remove the two park brake lever attaching nuts and remove the park brake lever assembly. 13. Disconnect the ACM wiring connector (Figure 5): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 14. Remove the remaining three (3) nuts that secure the ACM mounting bracket to the floor, disconnect the two (2) park brake lever switch wire harness clips from the ACM bracket and then remove the ACM and bracket assembly. 15. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 16. Loosely install the three (3) ACM attaching nuts. 17. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5709 18. Install the park brake lever assembly. 19. Tighten the four (4) ACM nuts and the remaining park brake lever nut to 115 in-lbs (12.5 N.m). 20. Connect the park brake lever switch electrical connector and attach the wiring clips to the ACM bracket. 21. Install both rear park brake cables into the equalizer. 22. Pull the park brake lever handle all the way up. 23. Firmly grasp the park brake lever locking pin (drill bit) and quickly remove it from the mechanism. 24. Cycle the park brake lever once to position the park brake cables. 25. Make sure that the park brake lever is fully raised and then install the center console assembly. 26. Install the front two (2) center console attaching screws located near the cup holders (Figure 1). 27. Install the two (2) screws at the bottom of the storage bin (Figure 2). 28. Install the two (2) outer lower console bracket bolts on each side of the storage bin and then install the bolt covers. 29. For Manual Transmission Equipped Vehicles: Install the shifter knob and fastener. 30. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 31. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 32. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Dakota (AN) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area around the center instrument panel support. 3. Remove the two (2) front center support bracket screws (Figure 6). 4. Remove the two (2) left side and one (1) right side support bracket screws (Figure 6). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5710 5. Remove the support bracket. 6. Remove the ground eyelet screw from the left side of the ACM bracket. 7. Disconnect the ACM wiring connector (Figure 7): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 8. Remove the three (3) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 8). 9. Remove the ACM and bracket assembly. 10. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 11. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 105 in-lbs (11.8 N.m). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5711 12. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 13. Install the ground eyelet screw to the left side of the ACM bracket. 14. Install the center instrument panel support bracket. 15. Install the two (2) left side and one (1) right side support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 16. Install the two (2) front center support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 17. Reinstall the floor carpet around the center instrument panel support. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Wrangler (TJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area under the heater-A/C housing floor duct and forward of the center floor console. 3. For vehicles equipped with ABS: Remove the ABS acceleration sensor from its mounting bracket and set aside (Figure 9). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5712 4. Remove the four (4) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 10). 5. Disconnect the ACM wiring connector (Figure 11): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 6. Slide the ACM and bracket assembly out from under the heater-A/C housing floor duct and remove it from the vehicle. 7. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 8. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 9. Tighten the four (4) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m) (Figure 10). 10. For vehicles equipped with ABS: Reinstall the ABS acceleration sensor (Figure 9). Tighten the sensor mounting bolts to 40 in-lbs (4.5 N.m). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5713 11. Reinstall the floor carpet under the heater-A/C floor duct. 12. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 13. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 14. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Grand Cherokee (ZJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the transmission shift lever handle by pulling straight up firmly and quickly. 3. Pry up the transmission shift indicator bezel with a trim stick (Figure 12). 4. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transmission shift indicator bezel from the console. 5. Pry up the transfer case shift indicator bezel with a trim stick (Figure 12). 6. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transfer case bezel from the console. 7. Remove the console attaching screws and then remove the console (Figure 12). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5714 8. Disconnect the ACM wiring connector (Figure 13): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 9. Remove the four (4) screws that secure the ACM mounting bracket to the floor transmission tunnel (Figure 14). 10. Remove the ACM and bracket assembly. 11. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 12. Tighten the four (4) ACM attaching screws to 95 in-lbs (10.7 N.m). 13. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 14. Install the console and secure it with the attaching screws (Figure 12). 15. Install the lamp socket into the transfer case shift bezel and then install the bezel into the console (Figure 12). 16. Install the lamp socket into the transmission shift indicator bezel and then install the bezel into the console (Figure 12). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5715 17. Install the transmission shift lever handle. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Viper GTS Coupe (SR) Vehicles: 1. Remove the left rear wheel and tire assembly. 2. Remove the left rear wheel well inner splash shield. 3. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 4. Remove the instrument panel center bezel and then disconnect the rear window defogger switch, the power window switches and the lighter (Figure 15). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5716 5. Remove the right and left knee blockers (Figure 16). 6. Remove the headlamp switch knob by inserting a paper clip in the hole under the knob and pushing gently to release the lock clip (Figure 16). 7. Remove the tilt steering handle. 8. Remove the upper steering column shroud. 9. Remove the instrument panel bezel (Figure 16). NOTE: Be careful not to break the headlamp switch lock tab when removing the I/P bezel. 10. Remove the two (2) radio mounting screws. 11. Remove the radio and disconnect the wire connector, coaxial cable and antenna cable. 12. Remove the radio from the vehicle. 13. Remove the HVAC control module. Only disconnect the vacuum and electrical connectors. Do not disconnect the cable. Set the control module aside. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5717 14. Reach through the radio opening and disconnect the ACM wiring connector (Figure 17): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 15. Remove the three (3) nuts that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 18). 16. Slide the ACM and bracket assembly out through the radio opening. 17. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 18. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m). 19. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 20. Connect the HVAC control head electrical and vacuum connectors. Install the HVAC control module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5718 21. Connect the radio wire connector, coaxial cable and antenna cable. 22. Install the radio into the instrument panel and tighten the two (2) mounting screws. 23. Install the instrument panel bezel (Figure 16). NOTE: Be careful when installing the I/P bezel. Do not break the headlamp switch lock tab. 24. Install the headlamp switch knob (Figure 16). 25. Install the upper steering column cover. 26. Install the tilt steering handle. 27. Install the right and left knee blockers (Figure 16). 28. Connect the rear window defogger switch, the power window switches and the lighter and then install the instrument panel center bezel (Figure 15). 29. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 30. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 31. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. 32. Install the left rear wheel well inner splash shield. 33. Install the left rear wheel and tire assembly. Completion Reporting and Reimbursement / Parts Return Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. Parts Return Initially, a small number of ACM and bracket assemblies are required to be returned to the Warranty Material Return Center. When an adequate number of returned parts have been accumulated, Parts Return Documents will no longer be generated and parts are to be discarded. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5719 CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dealer Service Instructions IMPORTANT Safety Recall # 731 -- Airbag Control Module ^ Effective immediately, this recall (# 731) cancels and supercedes Recall # 683 -- Airbag Control Module for 1997 Jeep Wrangler (TJ) vehicles. ^ This service requirement applies only to: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) ^ The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position. To correct this condition, the airbag control module (ACM) must be replaced. Parts Packages: ^ Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough ACM Packages to service about 25% of those vehicles. Owner Letter SAFETY RECALL TO REPLACE YOUR VEHICLE'S AIRBAG CONTROL MODULE Dear Chrysler Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1997 Plymouth and Dodge Neon; Dodge Dakota; Jeep Grand Cherokee and Wrangler; and 1996 Dodge Viper GTS Coupe vehicles. The problem is... The airbags on your vehicle (identified on the enclosed form), may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. What Chrysler and your dealer will do... Chrysler will repair your (vehicle) free of charge (parts and labor). To do this, your dealer will replace the airbag control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5720 If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5721 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5722 Connector Pin-Outs Component Index Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5723 Air Bag Control Module: Service Precautions Electrical Precautions Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5724 Air Bag Control Module: Description and Operation SYSTEM OPERATION Airbag Control Module Location The Airbag Control Module (ACM) contains the safing sensor and energy reserve capacitor. The safing sensor is located inside the ACM. The module is mounted on the tunnel/floor pan between the gear shift lever and the park brake lever. The safing sensor provides confirmation of a crash, but does not discriminate severity. The ACM monitors the system to determine the system readiness. The ACM contains on-board diagnostics, and will illuminate the AIRBAG warning lamp in the cluster when a fault occurs. The warning equipment is tested for 6 to 8 Seconds every time the vehicle is started. Driver And Passenger Airbag Module WARNING: NEVER DISASSEMBLE THE DRIVER OR PASSENGER AIRBAG MODULE, THERE ARE NO SERVICEABLE PARTS WITH IN THE MODULES. Driver Airbag The Driver Airbag Module located on the steering wheel is the most visible part of the system. The airbag module contains a housing to which the cushion, inflator and cover are attached to. The driver side inflator assembly is mounted from the back of the module housing. When supplied with the proper electrical signal the inflator assembly will produce a gas and discharge it directly into the cushion. A protective cover is fitted to the front of the Driver Airbag Module and forms a decorative cover in the center of the steering wheel. The Driver Airbag Module is mounted directly to the steering wheel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5725 Passengers Airbag The Passenger Airbag Module is located beneath the decorative cover of the instrument panel, facing the passenger seat. The passenger inflator assembly is within the module housing. The module is mounted to the instrument panel retainer and support structure. When supplied with the proper electrical signal the inflator will produce a gas and discharge it directly into the cushion. A protective cover is fitted into the instrument panel over the airbag module and forms a decorative cover. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5726 Air Bag Control Module: Service and Repair REMOVAL WARNING: - THE ACM CONTAINS A SAFING SENSOR WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT THE ACM ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. - DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION PROCEDURE. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR 2 MINUTES BEFORE REMOVING ANY AIRBAG COMPONENTS. CAUTION: Failure to follow the parking brake service procedures can result in damage to the parking brake mechanism. 1. Disconnect and isolate the battery negative cable. 2. Manual transaxle only, remove shifter knob fastener and remove shifter knob. Attaching Screws At Rear Of Center Console With/Without Arm Rest Attaching Screws At Rear Of Center Console With Arm Rest 3. Remove screws attaching rear of center console assembly to console bracket. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5727 Attaching Screws At Front Of Center Console 4. Remove the two screws located in cup holders, attaching front of center console assembly to console bracket. 5. Raise park brake hand lever assembly as high as it will go for required clearance to remove center console. 6. Remove center console assembly from vehicle. WARNING: THE AUTO ADJUSTING FEATURE OF THIS PARKING BRAKE LEVER ASSEMBLY CONTAINS A CLOCK SPRING LOADED TO APPROXIMATELY 20 POUNDS. DO NOT RELEASE THE AUTO ADJUSTER LOCKOUT DEVICE BEFORE INSTALLING CABLES INTO THE EQUALIZER. KEEP HANDS OUT OF AUTO ADJUSTER SECTOR AND PAWL AREA. FAILURE TO OBSERVE CAUTION IN HANDLING THIS MECHANISM COULD LEAD TO SERIOUS INJURY. WHEN REPAIRS TO THE PARK BRAKE HAND LEVER ASSEMBLY OR CABLES IS REQUIRED, THE AUTO ADJUSTER MUST BE RELOADED AND LOCKED OUT. 7. Lower park brake lever handle. Locking Pin Installed In Park Brake Mechanism 8. Grasp park brake lever output cable by hand and pull upward. Continue pulling on cable until a 3/16 in. drill bit can be inserted into handle and sector gear of park brake mechanism. This will lock the park brake mechanism and take tension off park brake cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5728 Locking Pin Installed In Park Brake Mechanism 9. Remove both rear park brake cables from the park brake cable equalizer. Brake Warning Lamp Connection To Park Brake Lever 10. Remove wiring harness electrical connector for brake warning light from park brake lever. Park Brake Lever Attachment To Console Bracket 11. Remove the two nuts attaching park brake lever to console bracket. Remove park brake lever mechanism from vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5729 Airbag Control Module 12. Remove module mounting nuts and remove module. ACM Connector 13. Disconnect ACM 23-PIN connector. 14. Remove Airbag Control Module. INSTALLATION 1. Connect ACM connector and ensure that the connector locking tab is engaged. CAUTION: USE SUPPLIED SCREWS ONLY 2. Position ACM (arrow pointing forward) in the console floor bracket, attach the nuts and tighten to 11 to 14 N.m (105 to 125 in. lbs.) torque. NOTE: The park brake lever can be in any position when releasing the auto adjuster. To ease installation of center console, it is advisable to pull park brake lever handle all the way up before removing lockout pin. 3. Place park brake lever on console bracket. Install and securely tighten the 2 attaching nuts. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5730 Park Brake Cables Properly Installed In Equalizer Rear Park Brake Cable Installation On Equalizer 4. Install both rear park brake cables into equalizer on park brake lever output cable. 5. Ensure that park brake cable is correctly installed and aligned with cable track on park brake lever. 6. Pull park brake lever handle all the way up. Removing Lockout Pin From Park Brake Lever Assembly 7. Firmly grasp park brake lever locking pin and quickly remove it from the park brake lever mechanism, This will allow the park brake lever mechanism to correctly adjust the park brake cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5731 Brake Warning Lamp Connection To Park Brake Lever 8. Connect electrical connector for brake warning lamp onto terminal on park brake lever assembly. 9. Cycle park brake lever once to position park brake cables. Then return the park brake lever its released position. Check the rear wheels of the vehicle. They should rotate freely without dragging. 10. Raise park brake lever to its fully engaged position. This is necessary to allow installation of the center console. 11. Install center console assembly. Attaching Screws At Rear Of Center Console With/Without Arm Rest Attaching Screws At Rear Of Center Console With Arm Rest Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5732 Attaching Screws At Front Of Center Console 12. Install the four center console assembly attaching screws. 13. Replace shifter knob and fastener. 14. Do not connect battery negative cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5737 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5738 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5739 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5740 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5741 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5742 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5743 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5744 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5745 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5746 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5747 PARTS REQUIRED: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5748 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5749 POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service Clockspring Assembly / Spiral Cable: Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 5754 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5755 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5756 Clockspring Assembly / Spiral Cable: Description and Operation SYSTEM OPERATION Clockspring The clockspring is mounted to the steering column behind the steering wheel. The clockspring is used to maintain a continuous electrical circuit between the wiring harness and the: Driver's airbag module - Speed control switches - Horn switch The clockspring consists of a flat, ribbon like, electrically conductive tape which winds and unwinds with the steering wheel rotation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5757 Clockspring Assembly / Spiral Cable: Adjustments If the rotating tape within the clockspring is not positioned properly with the steering wheel and the front wheels, the clockspring may fail during use. The following procedure MUST BE USED to center the clockspring if: - The clockspring is not known to be properly positioned - The front wheels were moved - The steering wheel was moved from the half turn (180 °) to the right (clockwise) position. WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION PROCEDURE. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR 2 MINUTES BEFORE REMOVING ANY AIR BAG COMPONENTS. 1. Remove clockspring, refer to Clockspring Removal. 2. Rotate the clockspring rotor in the CLOCKWISE DIRECTION to the end of travel. Do not apply excessive torque. 3. From the end of travel, rotate the rotor two full turns and a half in the counterclockwise direction. The horn wire and the squib wire should end up at the bottom. If not, rotate the rotor counter clockwise until the wires are properly orientated, but not more than half turn (180 °). Engage clockspring locking mechanism. 4. For installation, refer to Clockspring Installation 5. Do not connect battery negative cable. Refer to Diagnosis and Testing for Airbag System Test procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5758 Clockspring Assembly / Spiral Cable: Service and Repair REMOVAL WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION PROCEDURE. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR 2 MINUTES BEFORE REMOVING ANY AIRBAG COMPONENTS. 1. Place the front road wheels in the straight ahead position then: - Rotate the steering wheel half turn (180 °) to the right (clockwise) - Lock column with ignition lock cylinder. 2. Disconnect and isolate the battery negative cable. 3. Wait two minutes for the reserve capacitor to discharge before removing non-deployed module. 4. Remove speed control switch mounting screws, switches and disconnect the wire connectors or remove covers. 5. Remove the Driver Airbag Module attaching bolts from under the speed control switches or covers. 6. Lift module and disconnect the airbag and horn wire connectors. 7. Remove the steering wheel, refer to Steering and Suspension/Steering Wheel removal procedures. 8. Remove upper and lower steering column shrouds to gain access to clockspring wiring. 9. Disconnect the 2-way and 4-way connectors between the clockspring and the instrument panel wiring harness at the base of the clockspring. 10. Unlatch and remove clockspring assembly from steering shaft. The clockspring cannot be repaired, and must be replaced if faulty. 11. Rotate clockspring rotor a half turn (180 °) to the left (counter clockwise). 12. Lock the clockspring rotor in the center position as follows: Insert a paper clip wire through the hole in the rotor at the 10 O' Clock position and bend to prevent it from falling out. INSTALLATION 1. Confirm that: - The steering wheel position is a half turn (180 °) to the right (clockwise) - The column is locked with the ignition cylinder lock. - Check that the turn signal stalk is in the neutral position - When reusing the clockspring, remove locking wire and rotate clockspring rotor one half turn (180 °) to the right (clockwise). Locate the clock-spring on the steering shaft and push down on the rotor until the clockspring is fully seated on the steering column. - When installing a new clockspring remove grenade pin and rotate clockspring rotor one half turn (180 °) to the right (clockwise). Locate clock-spring on the steering shaft and push down on the rotor until the clockspring is fully seated on the steering wheel. 2. Connect the clockspring to the instrument panel harness, ensure wiring is properly routed. Then check that the connectors, locking tabs are properly engaged and the halo lamp wire is in position. 3. Install steering column shrouds. Be sure all wires are inside of shrouds. 4. Install steering wheel ensuring the fiats on hub align with the clockspring. Pull the horn, airbag and speed control leads through the larger slot. Ensure leads do not get pinched under the steering wheel. 5. Route speed control wires under and behind the airbag module mounting tabs. 6. Connect the horn lead wire and the airbag lead wire to the airbag module. 7. Install the airbag module and tighten bolts to 12 to 14 N.m (105 to 125 in. lbs.) torque. 8. Connect the speed control wires to the switches and install switches. Tighten screws to 2 N.m (20 in. lbs.) torque. 9. Do not connect the battery negative cable. Refer to Diagnosis and Testing for Airbag System Test procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations The airbag control module (ACM) is an electronic module that monitors the airbag system for proper operation, stores diagnostic trouble code (DTCs), controls the airbag warning lamp, and contains the safing sensor and accelerometer that is responsible for airbag deployment. The ACM is located on the floor pan between the gear shifter and the parking brake assembly. The ACM provides diagnostic information (DTCs) to the technician through the DRB Ill via the CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. NOTE: The warning lamp is hardwired to the ACM and there are no external impact sensors. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5766 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5767 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5768 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5769 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5770 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module Technical Service Bulletin # 731 Date: 970701 Recall - Airbag Control Module No. 731 July, 1997 To: All Dealers Subject: Safety Recall # 731 -- Airbag Control Module Models: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. To correct this condition, the airbag control module (ACM) must be replaced. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for service as determined by using DIAL System Function 70. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53, 70 and VIP All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time of recall implementation for dealer inquiry as needed. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 5780 Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough of each ACM Package to service about 25% of those vehicles. Each package contains one (1) ACM. Refer to the table above for the appropriate package application: Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Service Procedure For Neon (PL) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. For Manual Transmission Equipped Vehicles: Remove the shifter knob fastener and remove the shifter knob. 3. Remove the front two (2) center console attaching screws located near the cup holders (Figure 1). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 5781 4. Remove the two (2) screws at the bottom of the storage bin (Figure 2). 5. Remove the bolt access covers and the two lower console bracket bolts on each side of the console bin. 6. Raise the park brake hand lever as high as possible. 7. Remove the center console assembly. WARNING: The auto adjusting feature of the park brake lever assembly contains a clock spring loaded to approximately 20 lbs. DO NOT release the auto adjuster lock out device before installing the cables into the equalizer. Keep hands out of auto adjuster sector and pawl area. Failure to observe caution in handling this mechanism could lead to serious injury. 8. Lower the park brake handle. 9. Grasp the park brake lever output cable by hand and pull upward until a 3/16" drill bit can be inserted into the handle and sector gear mechanism (Figure 3). This will remove the tension from the park brake cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 5782 10. Remove both rear park brake cables from the park brake cable equalizer (Figure 4). 11. Disconnect the brake warning light electrical connector from the park brake lever switch. 12. Remove the two park brake lever attaching nuts and remove the park brake lever assembly. 13. Disconnect the ACM wiring connector (Figure 5): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 14. Remove the remaining three (3) nuts that secure the ACM mounting bracket to the floor, disconnect the two (2) park brake lever switch wire harness clips from the ACM bracket and then remove the ACM and bracket assembly. 15. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 16. Loosely install the three (3) ACM attaching nuts. 17. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 5783 18. Install the park brake lever assembly. 19. Tighten the four (4) ACM nuts and the remaining park brake lever nut to 115 in-lbs (12.5 N.m). 20. Connect the park brake lever switch electrical connector and attach the wiring clips to the ACM bracket. 21. Install both rear park brake cables into the equalizer. 22. Pull the park brake lever handle all the way up. 23. Firmly grasp the park brake lever locking pin (drill bit) and quickly remove it from the mechanism. 24. Cycle the park brake lever once to position the park brake cables. 25. Make sure that the park brake lever is fully raised and then install the center console assembly. 26. Install the front two (2) center console attaching screws located near the cup holders (Figure 1). 27. Install the two (2) screws at the bottom of the storage bin (Figure 2). 28. Install the two (2) outer lower console bracket bolts on each side of the storage bin and then install the bolt covers. 29. For Manual Transmission Equipped Vehicles: Install the shifter knob and fastener. 30. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 31. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 32. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Dakota (AN) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area around the center instrument panel support. 3. Remove the two (2) front center support bracket screws (Figure 6). 4. Remove the two (2) left side and one (1) right side support bracket screws (Figure 6). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 5784 5. Remove the support bracket. 6. Remove the ground eyelet screw from the left side of the ACM bracket. 7. Disconnect the ACM wiring connector (Figure 7): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 8. Remove the three (3) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 8). 9. Remove the ACM and bracket assembly. 10. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 11. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 105 in-lbs (11.8 N.m). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 5785 12. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 13. Install the ground eyelet screw to the left side of the ACM bracket. 14. Install the center instrument panel support bracket. 15. Install the two (2) left side and one (1) right side support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 16. Install the two (2) front center support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 17. Reinstall the floor carpet around the center instrument panel support. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Wrangler (TJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area under the heater-A/C housing floor duct and forward of the center floor console. 3. For vehicles equipped with ABS: Remove the ABS acceleration sensor from its mounting bracket and set aside (Figure 9). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 5786 4. Remove the four (4) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 10). 5. Disconnect the ACM wiring connector (Figure 11): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 6. Slide the ACM and bracket assembly out from under the heater-A/C housing floor duct and remove it from the vehicle. 7. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 8. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 9. Tighten the four (4) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m) (Figure 10). 10. For vehicles equipped with ABS: Reinstall the ABS acceleration sensor (Figure 9). Tighten the sensor mounting bolts to 40 in-lbs (4.5 N.m). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 5787 11. Reinstall the floor carpet under the heater-A/C floor duct. 12. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 13. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 14. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Grand Cherokee (ZJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the transmission shift lever handle by pulling straight up firmly and quickly. 3. Pry up the transmission shift indicator bezel with a trim stick (Figure 12). 4. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transmission shift indicator bezel from the console. 5. Pry up the transfer case shift indicator bezel with a trim stick (Figure 12). 6. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transfer case bezel from the console. 7. Remove the console attaching screws and then remove the console (Figure 12). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 5788 8. Disconnect the ACM wiring connector (Figure 13): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 9. Remove the four (4) screws that secure the ACM mounting bracket to the floor transmission tunnel (Figure 14). 10. Remove the ACM and bracket assembly. 11. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 12. Tighten the four (4) ACM attaching screws to 95 in-lbs (10.7 N.m). 13. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 14. Install the console and secure it with the attaching screws (Figure 12). 15. Install the lamp socket into the transfer case shift bezel and then install the bezel into the console (Figure 12). 16. Install the lamp socket into the transmission shift indicator bezel and then install the bezel into the console (Figure 12). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 5789 17. Install the transmission shift lever handle. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Viper GTS Coupe (SR) Vehicles: 1. Remove the left rear wheel and tire assembly. 2. Remove the left rear wheel well inner splash shield. 3. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 4. Remove the instrument panel center bezel and then disconnect the rear window defogger switch, the power window switches and the lighter (Figure 15). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 5790 5. Remove the right and left knee blockers (Figure 16). 6. Remove the headlamp switch knob by inserting a paper clip in the hole under the knob and pushing gently to release the lock clip (Figure 16). 7. Remove the tilt steering handle. 8. Remove the upper steering column shroud. 9. Remove the instrument panel bezel (Figure 16). NOTE: Be careful not to break the headlamp switch lock tab when removing the I/P bezel. 10. Remove the two (2) radio mounting screws. 11. Remove the radio and disconnect the wire connector, coaxial cable and antenna cable. 12. Remove the radio from the vehicle. 13. Remove the HVAC control module. Only disconnect the vacuum and electrical connectors. Do not disconnect the cable. Set the control module aside. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 5791 14. Reach through the radio opening and disconnect the ACM wiring connector (Figure 17): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 15. Remove the three (3) nuts that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 18). 16. Slide the ACM and bracket assembly out through the radio opening. 17. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 18. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m). 19. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 20. Connect the HVAC control head electrical and vacuum connectors. Install the HVAC control module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 5792 21. Connect the radio wire connector, coaxial cable and antenna cable. 22. Install the radio into the instrument panel and tighten the two (2) mounting screws. 23. Install the instrument panel bezel (Figure 16). NOTE: Be careful when installing the I/P bezel. Do not break the headlamp switch lock tab. 24. Install the headlamp switch knob (Figure 16). 25. Install the upper steering column cover. 26. Install the tilt steering handle. 27. Install the right and left knee blockers (Figure 16). 28. Connect the rear window defogger switch, the power window switches and the lighter and then install the instrument panel center bezel (Figure 15). 29. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 30. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 31. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. 32. Install the left rear wheel well inner splash shield. 33. Install the left rear wheel and tire assembly. Completion Reporting and Reimbursement / Parts Return Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. Parts Return Initially, a small number of ACM and bracket assemblies are required to be returned to the Warranty Material Return Center. When an adequate number of returned parts have been accumulated, Parts Return Documents will no longer be generated and parts are to be discarded. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 5793 CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dealer Service Instructions IMPORTANT Safety Recall # 731 -- Airbag Control Module ^ Effective immediately, this recall (# 731) cancels and supercedes Recall # 683 -- Airbag Control Module for 1997 Jeep Wrangler (TJ) vehicles. ^ This service requirement applies only to: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) ^ The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position. To correct this condition, the airbag control module (ACM) must be replaced. Parts Packages: ^ Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough ACM Packages to service about 25% of those vehicles. Owner Letter SAFETY RECALL TO REPLACE YOUR VEHICLE'S AIRBAG CONTROL MODULE Dear Chrysler Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1997 Plymouth and Dodge Neon; Dodge Dakota; Jeep Grand Cherokee and Wrangler; and 1996 Dodge Viper GTS Coupe vehicles. The problem is... The airbags on your vehicle (identified on the enclosed form), may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. What Chrysler and your dealer will do... Chrysler will repair your (vehicle) free of charge (parts and labor). To do this, your dealer will replace the airbag control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 5794 If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module Technical Service Bulletin # 731 Date: 970701 Recall - Airbag Control Module No. 731 July, 1997 To: All Dealers Subject: Safety Recall # 731 -- Airbag Control Module Models: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. To correct this condition, the airbag control module (ACM) must be replaced. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for service as determined by using DIAL System Function 70. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53, 70 and VIP All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time of recall implementation for dealer inquiry as needed. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5800 Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough of each ACM Package to service about 25% of those vehicles. Each package contains one (1) ACM. Refer to the table above for the appropriate package application: Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Service Procedure For Neon (PL) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. For Manual Transmission Equipped Vehicles: Remove the shifter knob fastener and remove the shifter knob. 3. Remove the front two (2) center console attaching screws located near the cup holders (Figure 1). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5801 4. Remove the two (2) screws at the bottom of the storage bin (Figure 2). 5. Remove the bolt access covers and the two lower console bracket bolts on each side of the console bin. 6. Raise the park brake hand lever as high as possible. 7. Remove the center console assembly. WARNING: The auto adjusting feature of the park brake lever assembly contains a clock spring loaded to approximately 20 lbs. DO NOT release the auto adjuster lock out device before installing the cables into the equalizer. Keep hands out of auto adjuster sector and pawl area. Failure to observe caution in handling this mechanism could lead to serious injury. 8. Lower the park brake handle. 9. Grasp the park brake lever output cable by hand and pull upward until a 3/16" drill bit can be inserted into the handle and sector gear mechanism (Figure 3). This will remove the tension from the park brake cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5802 10. Remove both rear park brake cables from the park brake cable equalizer (Figure 4). 11. Disconnect the brake warning light electrical connector from the park brake lever switch. 12. Remove the two park brake lever attaching nuts and remove the park brake lever assembly. 13. Disconnect the ACM wiring connector (Figure 5): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 14. Remove the remaining three (3) nuts that secure the ACM mounting bracket to the floor, disconnect the two (2) park brake lever switch wire harness clips from the ACM bracket and then remove the ACM and bracket assembly. 15. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 16. Loosely install the three (3) ACM attaching nuts. 17. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5803 18. Install the park brake lever assembly. 19. Tighten the four (4) ACM nuts and the remaining park brake lever nut to 115 in-lbs (12.5 N.m). 20. Connect the park brake lever switch electrical connector and attach the wiring clips to the ACM bracket. 21. Install both rear park brake cables into the equalizer. 22. Pull the park brake lever handle all the way up. 23. Firmly grasp the park brake lever locking pin (drill bit) and quickly remove it from the mechanism. 24. Cycle the park brake lever once to position the park brake cables. 25. Make sure that the park brake lever is fully raised and then install the center console assembly. 26. Install the front two (2) center console attaching screws located near the cup holders (Figure 1). 27. Install the two (2) screws at the bottom of the storage bin (Figure 2). 28. Install the two (2) outer lower console bracket bolts on each side of the storage bin and then install the bolt covers. 29. For Manual Transmission Equipped Vehicles: Install the shifter knob and fastener. 30. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 31. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 32. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Dakota (AN) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area around the center instrument panel support. 3. Remove the two (2) front center support bracket screws (Figure 6). 4. Remove the two (2) left side and one (1) right side support bracket screws (Figure 6). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5804 5. Remove the support bracket. 6. Remove the ground eyelet screw from the left side of the ACM bracket. 7. Disconnect the ACM wiring connector (Figure 7): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 8. Remove the three (3) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 8). 9. Remove the ACM and bracket assembly. 10. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 11. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 105 in-lbs (11.8 N.m). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5805 12. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 13. Install the ground eyelet screw to the left side of the ACM bracket. 14. Install the center instrument panel support bracket. 15. Install the two (2) left side and one (1) right side support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 16. Install the two (2) front center support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 17. Reinstall the floor carpet around the center instrument panel support. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Wrangler (TJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area under the heater-A/C housing floor duct and forward of the center floor console. 3. For vehicles equipped with ABS: Remove the ABS acceleration sensor from its mounting bracket and set aside (Figure 9). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5806 4. Remove the four (4) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 10). 5. Disconnect the ACM wiring connector (Figure 11): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 6. Slide the ACM and bracket assembly out from under the heater-A/C housing floor duct and remove it from the vehicle. 7. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 8. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 9. Tighten the four (4) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m) (Figure 10). 10. For vehicles equipped with ABS: Reinstall the ABS acceleration sensor (Figure 9). Tighten the sensor mounting bolts to 40 in-lbs (4.5 N.m). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5807 11. Reinstall the floor carpet under the heater-A/C floor duct. 12. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 13. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 14. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Grand Cherokee (ZJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the transmission shift lever handle by pulling straight up firmly and quickly. 3. Pry up the transmission shift indicator bezel with a trim stick (Figure 12). 4. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transmission shift indicator bezel from the console. 5. Pry up the transfer case shift indicator bezel with a trim stick (Figure 12). 6. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transfer case bezel from the console. 7. Remove the console attaching screws and then remove the console (Figure 12). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5808 8. Disconnect the ACM wiring connector (Figure 13): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 9. Remove the four (4) screws that secure the ACM mounting bracket to the floor transmission tunnel (Figure 14). 10. Remove the ACM and bracket assembly. 11. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 12. Tighten the four (4) ACM attaching screws to 95 in-lbs (10.7 N.m). 13. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 14. Install the console and secure it with the attaching screws (Figure 12). 15. Install the lamp socket into the transfer case shift bezel and then install the bezel into the console (Figure 12). 16. Install the lamp socket into the transmission shift indicator bezel and then install the bezel into the console (Figure 12). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5809 17. Install the transmission shift lever handle. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Viper GTS Coupe (SR) Vehicles: 1. Remove the left rear wheel and tire assembly. 2. Remove the left rear wheel well inner splash shield. 3. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 4. Remove the instrument panel center bezel and then disconnect the rear window defogger switch, the power window switches and the lighter (Figure 15). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5810 5. Remove the right and left knee blockers (Figure 16). 6. Remove the headlamp switch knob by inserting a paper clip in the hole under the knob and pushing gently to release the lock clip (Figure 16). 7. Remove the tilt steering handle. 8. Remove the upper steering column shroud. 9. Remove the instrument panel bezel (Figure 16). NOTE: Be careful not to break the headlamp switch lock tab when removing the I/P bezel. 10. Remove the two (2) radio mounting screws. 11. Remove the radio and disconnect the wire connector, coaxial cable and antenna cable. 12. Remove the radio from the vehicle. 13. Remove the HVAC control module. Only disconnect the vacuum and electrical connectors. Do not disconnect the cable. Set the control module aside. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5811 14. Reach through the radio opening and disconnect the ACM wiring connector (Figure 17): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 15. Remove the three (3) nuts that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 18). 16. Slide the ACM and bracket assembly out through the radio opening. 17. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 18. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m). 19. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 20. Connect the HVAC control head electrical and vacuum connectors. Install the HVAC control module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5812 21. Connect the radio wire connector, coaxial cable and antenna cable. 22. Install the radio into the instrument panel and tighten the two (2) mounting screws. 23. Install the instrument panel bezel (Figure 16). NOTE: Be careful when installing the I/P bezel. Do not break the headlamp switch lock tab. 24. Install the headlamp switch knob (Figure 16). 25. Install the upper steering column cover. 26. Install the tilt steering handle. 27. Install the right and left knee blockers (Figure 16). 28. Connect the rear window defogger switch, the power window switches and the lighter and then install the instrument panel center bezel (Figure 15). 29. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 30. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 31. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. 32. Install the left rear wheel well inner splash shield. 33. Install the left rear wheel and tire assembly. Completion Reporting and Reimbursement / Parts Return Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. Parts Return Initially, a small number of ACM and bracket assemblies are required to be returned to the Warranty Material Return Center. When an adequate number of returned parts have been accumulated, Parts Return Documents will no longer be generated and parts are to be discarded. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5813 CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dealer Service Instructions IMPORTANT Safety Recall # 731 -- Airbag Control Module ^ Effective immediately, this recall (# 731) cancels and supercedes Recall # 683 -- Airbag Control Module for 1997 Jeep Wrangler (TJ) vehicles. ^ This service requirement applies only to: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) ^ The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position. To correct this condition, the airbag control module (ACM) must be replaced. Parts Packages: ^ Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough ACM Packages to service about 25% of those vehicles. Owner Letter SAFETY RECALL TO REPLACE YOUR VEHICLE'S AIRBAG CONTROL MODULE Dear Chrysler Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1997 Plymouth and Dodge Neon; Dodge Dakota; Jeep Grand Cherokee and Wrangler; and 1996 Dodge Viper GTS Coupe vehicles. The problem is... The airbags on your vehicle (identified on the enclosed form), may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. What Chrysler and your dealer will do... Chrysler will repair your (vehicle) free of charge (parts and labor). To do this, your dealer will replace the airbag control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 5814 If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5815 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5816 Connector Pin-Outs Component Index Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5817 Air Bag Control Module: Service Precautions Electrical Precautions Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5818 Air Bag Control Module: Description and Operation SYSTEM OPERATION Airbag Control Module Location The Airbag Control Module (ACM) contains the safing sensor and energy reserve capacitor. The safing sensor is located inside the ACM. The module is mounted on the tunnel/floor pan between the gear shift lever and the park brake lever. The safing sensor provides confirmation of a crash, but does not discriminate severity. The ACM monitors the system to determine the system readiness. The ACM contains on-board diagnostics, and will illuminate the AIRBAG warning lamp in the cluster when a fault occurs. The warning equipment is tested for 6 to 8 Seconds every time the vehicle is started. Driver And Passenger Airbag Module WARNING: NEVER DISASSEMBLE THE DRIVER OR PASSENGER AIRBAG MODULE, THERE ARE NO SERVICEABLE PARTS WITH IN THE MODULES. Driver Airbag The Driver Airbag Module located on the steering wheel is the most visible part of the system. The airbag module contains a housing to which the cushion, inflator and cover are attached to. The driver side inflator assembly is mounted from the back of the module housing. When supplied with the proper electrical signal the inflator assembly will produce a gas and discharge it directly into the cushion. A protective cover is fitted to the front of the Driver Airbag Module and forms a decorative cover in the center of the steering wheel. The Driver Airbag Module is mounted directly to the steering wheel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5819 Passengers Airbag The Passenger Airbag Module is located beneath the decorative cover of the instrument panel, facing the passenger seat. The passenger inflator assembly is within the module housing. The module is mounted to the instrument panel retainer and support structure. When supplied with the proper electrical signal the inflator will produce a gas and discharge it directly into the cushion. A protective cover is fitted into the instrument panel over the airbag module and forms a decorative cover. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5820 Air Bag Control Module: Service and Repair REMOVAL WARNING: - THE ACM CONTAINS A SAFING SENSOR WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT THE ACM ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. - DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION PROCEDURE. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR 2 MINUTES BEFORE REMOVING ANY AIRBAG COMPONENTS. CAUTION: Failure to follow the parking brake service procedures can result in damage to the parking brake mechanism. 1. Disconnect and isolate the battery negative cable. 2. Manual transaxle only, remove shifter knob fastener and remove shifter knob. Attaching Screws At Rear Of Center Console With/Without Arm Rest Attaching Screws At Rear Of Center Console With Arm Rest 3. Remove screws attaching rear of center console assembly to console bracket. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5821 Attaching Screws At Front Of Center Console 4. Remove the two screws located in cup holders, attaching front of center console assembly to console bracket. 5. Raise park brake hand lever assembly as high as it will go for required clearance to remove center console. 6. Remove center console assembly from vehicle. WARNING: THE AUTO ADJUSTING FEATURE OF THIS PARKING BRAKE LEVER ASSEMBLY CONTAINS A CLOCK SPRING LOADED TO APPROXIMATELY 20 POUNDS. DO NOT RELEASE THE AUTO ADJUSTER LOCKOUT DEVICE BEFORE INSTALLING CABLES INTO THE EQUALIZER. KEEP HANDS OUT OF AUTO ADJUSTER SECTOR AND PAWL AREA. FAILURE TO OBSERVE CAUTION IN HANDLING THIS MECHANISM COULD LEAD TO SERIOUS INJURY. WHEN REPAIRS TO THE PARK BRAKE HAND LEVER ASSEMBLY OR CABLES IS REQUIRED, THE AUTO ADJUSTER MUST BE RELOADED AND LOCKED OUT. 7. Lower park brake lever handle. Locking Pin Installed In Park Brake Mechanism 8. Grasp park brake lever output cable by hand and pull upward. Continue pulling on cable until a 3/16 in. drill bit can be inserted into handle and sector gear of park brake mechanism. This will lock the park brake mechanism and take tension off park brake cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5822 Locking Pin Installed In Park Brake Mechanism 9. Remove both rear park brake cables from the park brake cable equalizer. Brake Warning Lamp Connection To Park Brake Lever 10. Remove wiring harness electrical connector for brake warning light from park brake lever. Park Brake Lever Attachment To Console Bracket 11. Remove the two nuts attaching park brake lever to console bracket. Remove park brake lever mechanism from vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5823 Airbag Control Module 12. Remove module mounting nuts and remove module. ACM Connector 13. Disconnect ACM 23-PIN connector. 14. Remove Airbag Control Module. INSTALLATION 1. Connect ACM connector and ensure that the connector locking tab is engaged. CAUTION: USE SUPPLIED SCREWS ONLY 2. Position ACM (arrow pointing forward) in the console floor bracket, attach the nuts and tighten to 11 to 14 N.m (105 to 125 in. lbs.) torque. NOTE: The park brake lever can be in any position when releasing the auto adjuster. To ease installation of center console, it is advisable to pull park brake lever handle all the way up before removing lockout pin. 3. Place park brake lever on console bracket. Install and securely tighten the 2 attaching nuts. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5824 Park Brake Cables Properly Installed In Equalizer Rear Park Brake Cable Installation On Equalizer 4. Install both rear park brake cables into equalizer on park brake lever output cable. 5. Ensure that park brake cable is correctly installed and aligned with cable track on park brake lever. 6. Pull park brake lever handle all the way up. Removing Lockout Pin From Park Brake Lever Assembly 7. Firmly grasp park brake lever locking pin and quickly remove it from the park brake lever mechanism, This will allow the park brake lever mechanism to correctly adjust the park brake cables. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5825 Brake Warning Lamp Connection To Park Brake Lever 8. Connect electrical connector for brake warning lamp onto terminal on park brake lever assembly. 9. Cycle park brake lever once to position park brake cables. Then return the park brake lever its released position. Check the rear wheels of the vehicle. They should rotate freely without dragging. 10. Raise park brake lever to its fully engaged position. This is necessary to allow installation of the center console. 11. Install center console assembly. Attaching Screws At Rear Of Center Console With/Without Arm Rest Attaching Screws At Rear Of Center Console With Arm Rest Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5826 Attaching Screws At Front Of Center Console 12. Install the four center console assembly attaching screws. 13. Replace shifter knob and fastener. 14. Do not connect battery negative cable. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components . Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 5832 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming 1. Verify that the negative battery cable is disconnected and isolated. 2. Connect scan tool (DRB) to Data Link connector, located at right side of the steering column and at the lower edge of the lower instrument panel. 3. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 4. After checking that no one is inside the vehicle, connect the battery negative terminal. 5. Using the scan tool, read and record active diagnostic code data. 6. Read and record any stored diagnostic codes. 7. Refer to the airbag system Diagnostic Test if any diagnostic codes are found in Step 5 or Step 6. 8. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the airbag system Diagnostic Test. If the airbag warning lamp either fails to light with the ignition switch ON, or the light goes on and stays on, there is a system malfunction. Refer to the airbag system Diagnostic Test. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Tether Installation NUMBER: 23-029-08 GROUP: Body DATE: October 24, 2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. B, DATED NOVEMBER 24, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DEALERS PLEASE NOTE, THIS IS REIMBURSABLE REGARDLESS OF VEHICLE AGE OR MILEAGE. SUBJECT: Child Seat Tether Anchor Installation OVERVIEW: This bulletin describes procedures to install Child Seat Tether Anchors based on Customer Request. NOTE: Dealers are encouraged to honor any customers request for the installation of the Child Seat Tether Anchors and Dealer reimbursement will be made by Chrysler regardless of vehicle age or mileage. See the Warranty Policy and Procedure Manual and or Warranty Bulletin D-08-33 for reimbursement detail. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shawdow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5838 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year and later. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. Chrysler is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. NOTE: This bulletin is provided to identify the parts and labor operation numbers necessary to install a Child Seat Tether Anchor. Each dealer is encouraged to install these kits based on customer request and Chrysler will reimburse any Chrysler / Dodge / or Jeep dealer installing these kits regardless of vehicle age or mileage. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5839 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5840 PARTS REQUIRED: POLICY: Customer Satisfaction, Reimbursable regardless of mileage or age. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5841 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5842 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5843 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5844 Child Seat Tether Attachment: Technical Service Bulletins Child Seat Tether Anchor - Labor/Parts Identification NUMBER: 23-35-99 Rev. A GROUP: Body DATE: Oct. 1, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-35-99 DATED SEPTEMBER 3, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES IN SOME TIME ALLOWANCES. SUBJECT: Child Seat Tether Anchors NOTE: THIS BULLETIN DOES NOT APPLY TO DAIMLERCHRYSLER CANADA DEALERS. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) LeBaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2000 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light truck in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5845 detailed instruction sheet. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5846 PARTS REQUIRED: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5847 POLICY: Customer Satisfaction Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5848 TIME ALLOWANCE: Failure Code: CG - Customer Satisfaction Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5849 Child Seat Tether Attachment: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5850 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5851 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5852 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5853 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5854 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Interior - Seat Belt Cinch Bar Service Seat Belt: Technical Service Bulletins Interior - Seat Belt Cinch Bar Service NUMBER: 08-010-03 GROUP: Electrical DATE: Apr.25, 2003 SUBJECT: Seat Belt Cinch Bar Service MODELS: 2001 - 2003 (AB) Ram Van/Wagon (Front Passenger Seat Belt Only) 1994 (BR) Ram Pickup 1996-2002 (BR/BE) Ram Pickup 2001 - 2003 (DN) Durango (Front Passenger Seat Belt Only) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 1996 - 2000 (JX) Sebring Convertible 1995 - 2003 (PL) Neon/SX 2.0 2001 - 2003 (PT) PT Cruiser DISCUSSION: Any time the seat belt cinch bar (Fig. 1) is loose, missing or damaged it is no longer necessary to replace the seat belt assembly. Cinch bar repair kits are now available for the vehicles listed. If any component of the seat belt assembly has been damaged due to collision, the entire assembly must be replaced. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Interior - Seat Belt Cinch Bar Service > Page 5859 NOTE: THE CINCH BAR, CINCH BAR COVER OR ANY OTHER COMPONENT OF THE SEAT BELT ASSEMBLY MUST NEVER BE PAINTED. NOTE: INSTALLATION INSTRUCTIONS ARE INCLUDED WITH EACH KIT. PARTS REQUIRED: NOTE: SELECT THE COLOR CLOSEST TO THE SEAT BELT ASSEMBLY COLOR. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation CIRCUIT OPERATION The fasten seat belt indicator is used with the warning chime to indicate to the operator to fasten the seat belt. There is a switch located in the drivers side B-pillar that is normally OPEN with the seat belt buckled. If the seat belt is not buckled the switch CLOSES and a ground path is completed from the G10 circuit to the Z1 circuit. This will illuminate the lamp in the instrument cluster. When the ignition switch is moved to the START position the lamp will illuminate. Logic internal to the instrument cluster determines the length of time. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5868 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5869 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5870 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5871 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5872 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5873 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5874 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5875 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5876 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5877 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5878 PARTS REQUIRED: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5879 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5880 POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations The airbag control module (ACM) is an electronic module that monitors the airbag system for proper operation, stores diagnostic trouble code (DTCs), controls the airbag warning lamp, and contains the safing sensor and accelerometer that is responsible for airbag deployment. The ACM is located on the floor pan between the gear shifter and the parking brake assembly. The ACM provides diagnostic information (DTCs) to the technician through the DRB Ill via the CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. NOTE: The warning lamp is hardwired to the ACM and there are no external impact sensors. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Testing and Inspection Antenna: Testing and Inspection Bench Test For Antenna Malfunction It is also possible to check short or open circuits with an ohmmeter or continuity light once the antenna has been removed from the vehicle. Antenna Bench Test Points 1. Continuity should he present between the tip of the mast and radio lead. 2. No continuity should be observed or a very high resistance of several megohms between the ground shell of the connector and radio end pin. 3. Continuity should be observed between the ground shell of the connector and the mounting bracket. Wiggle cable over its entire length to reveal intermittent short or open circuits during step 1, 2 and 3. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Testing and Inspection > Page 5888 Antenna: Service and Repair REMOVAL Antenna Mast Removal - Typical Antenna Mast Removal-Export 1. Remove antenna mast by unscrewing mast from antenna body. 2. Locate the antenna lead disconnect in the instrument panel wire harness above the right kick panel. Disconnect the antenna cable from cable lead. Antenna Mounting 3. Unfasten push pins from the rear of the plastic inner fender shield and move shield to gain access to mounting screws. 4. Remove mounting screw and remove antenna base and cable assembly from under the fender. INSTALLATION 1. Align antenna adapter tongue with grove in the fender hole and push adapter into fender. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Testing and Inspection > Page 5889 2. From under the fender, push the antenna base and cable assembly through the adapter in the fender. Tighten mounting screw to 7 N.m (75 in. lbs.). 3. Seat the grommet in the side panel and connect the cable to the instrument panel harness connector. 4. Install the plastic inner fender shield. 5. Connect the antenna cable to the cable lead. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Replacement Keyless Entry Module: Service and Repair Replacement REMOVAL 1. Remove the right trim panel. 2. Disconnect wire connector from RKE module. RKE Module Location 3. Remove screws holding RKE module to instrument panel assembly. 4. Remove module. INSTALLATION - For installation, reverse above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Replacement > Page 5896 Keyless Entry Module: Service and Repair Program Remote Keyless Entry Module 1. Retrieve the programming line from the upper edge of the passenger side cowl trim panel. The RKE Programming Line is a green wire with a red bullet connector. 2. Using a jumper wire, ground the RKE programming line. 3. Turn ignition switch to the ON position. 4. Press any button on the transmitter to set code. The locks will cycle to confirm programming. If there is a second transmitter it must be set at this time. Press any button on the second transmitter and wait for the locks to cycle to confirm programming. 5. Disconnect the programming line from ground. This returns the system to its normal operation mode. 6. Replace all removed components. Return programming line to its original position. Check for system operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Programming Connector > Component Information > Locations Keyless Entry Programming Connector: Locations Retrieve the programming line from the upper edge of the passenger side cowl trim panel. The RKE Programming Line is a GREEN wire with a RED BULLET CONNECTOR. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure Keyless Entry Transmitter Battery: Customer Interest RKE Transmitter - Premature Battery Failure NO: 08-39-97 GROUP: Electrical DATE: Nov. 28, 1997 SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely MODELS: 1997 - 1998 (AB) Ram Van/Wagon 1997 - 1998 (AN) Dakota/Dakota Cab & Chassis 1998 (BRIBE)Ram Truck 1998 (DN) Durango 1997 (LH) Concorde/Intrepid/LHS/Vision 1997 - 1998 (NS) Town & Country/Caravan/Voyager 1997 - 1998 (PL) Neon 1997 (PR) Prowler 1997 - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX). SYMPTOM/CONDITION: Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH 0815XX, perform the Repair Procedure. PARTS REQUIRED: AR 04686366 Transmitter, RKE- NS, PL & PR AR 04759136AB Transmitter, RKE- LH AR 56007049 Transmitter, RKE- AB & 1997 AN AR 56008761 Transmitter 1, RKE- ZJ & DN AR 56008762 Transmitter 2, RKE- ZJ AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN REPAIR PROCEDURE: This bulletin involves replacing the RKE transmitter(s). 1. Replace RKE transmitter(s) that have discharged batteries. 2. Program the RKE transmitter(s) to the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-28-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure Keyless Entry Transmitter Battery: All Technical Service Bulletins RKE Transmitter - Premature Battery Failure NO: 08-39-97 GROUP: Electrical DATE: Nov. 28, 1997 SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely MODELS: 1997 - 1998 (AB) Ram Van/Wagon 1997 - 1998 (AN) Dakota/Dakota Cab & Chassis 1998 (BRIBE)Ram Truck 1998 (DN) Durango 1997 (LH) Concorde/Intrepid/LHS/Vision 1997 - 1998 (NS) Town & Country/Caravan/Voyager 1997 - 1998 (PL) Neon 1997 (PR) Prowler 1997 - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX). SYMPTOM/CONDITION: Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH 0815XX, perform the Repair Procedure. PARTS REQUIRED: AR 04686366 Transmitter, RKE- NS, PL & PR AR 04759136AB Transmitter, RKE- LH AR 56007049 Transmitter, RKE- AB & 1997 AN AR 56008761 Transmitter 1, RKE- ZJ & DN AR 56008762 Transmitter 2, RKE- ZJ AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN REPAIR PROCEDURE: This bulletin involves replacing the RKE transmitter(s). 1. Replace RKE transmitter(s) that have discharged batteries. 2. Program the RKE transmitter(s) to the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-28-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5918 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5919 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5920 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5925 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5926 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5927 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > CD Player - CD Compatibility Compact Disc Player (CD): Technical Service Bulletins CD Player - CD Compatibility BULLETIN NUMBER: 08-11-00 GROUP: Electrical DATE: March 24, 2000 SUBJECT: Recordable Compact Discs Used in Automotive CD players MODELS: 1989 - 2000 (AB) Ram Van/Wagon 1989 - 2000 (AN) Dakota 1994 - 2000 (BR/BE) Ram Truck 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GT 1997 - 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1997 - 2000 (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee DISCUSSION: Some recordable compact disc media, such as CD-R and CD-RW, may not comply with the standard CD format used in automotive CD players. When these CD's are used, customers may encounter error messages, skipping, or delaminating of the labels, which can cause an eject failure. It is important to question whether these kinds of CD media are being used. When customers encounter these symptoms, check the system with a known playable CD. Explain that the media may not be compatible with some automotive CD players. Replacing or exchanging the CD player will not address these issues. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation Speaker: Description and Operation CIRCUIT OPERATION Circuit X53 feeds the speaker in the left front door. Circuit X55 is the return from the speaker to the radio. On the premium system the X53 and X55 circuits are connected in with the instrument panel speaker. Circuit X54 feeds the speaker in the right front door. Circuit X56 is the return from the speaker to the radio. On the premium system the X54 and X56 circuits are connected in with the instrument panel speaker. Circuit X51 feeds the left rear speaker. Circuit X57 is the return from the speaker to the radio. Circuit X52 feeds the right rear speaker. Circuit X5S is the return from the speaker to the radio. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Page 5936 Speaker: Testing and Inspection - Circuit M1 also powers the vanity lamps, glove box lamp, time delay relay, dome lamps, underhood lamp, cargo lamp, and power mirrors. - If the radio does not operate, check for blown fuses in circuits A1 and X12. - Circuits A3 and F3.3 feed the L7 circuit. - If the radio illumination lamps do not operate, check for blown fuses in circuits E2, F33, and A3. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Page 5937 Speaker: Service and Repair Instrument Panel Speaker REMOVAL Instrument Panel Speakers 1. Remove instrument panel top cover and cluster bezel. 2. Remove speaker retaining screws. 3. Remove speaker and disconnect wire connector. INSTALLATION For installation reverse the above procedures. Front Door Speaker REMOVAL 1. Remove door trim panel. Front Door Speaker 2. Remove three speaker retaining screws. 3. Remove speaker assembly and disconnect wire connector. INSTALLATION For installation reverse the above procedures. Rear Shelf Speaker REMOVAL 1. Remove rear seat and seat back. Remove seat cushion, seat back and seat belt anchor bolts. 2. Pry out the seat belt trim bezel along the rearward edge. 3. Partially remove the shelf trim panel slipping it down to the seat back position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Page 5938 Rear Shelf Speakers 4. Remove four speaker retaining screws. 5. Remove speaker and disconnect wire connector. INSTALLATION For installation reverse the above procedures. Position speakers so that the wire connectors are pointing to the drivers side of car. Tighten the seat belt anchor bolts to the proper torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Replacement Keyless Entry Module: Service and Repair Replacement REMOVAL 1. Remove the right trim panel. 2. Disconnect wire connector from RKE module. RKE Module Location 3. Remove screws holding RKE module to instrument panel assembly. 4. Remove module. INSTALLATION - For installation, reverse above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Replacement > Page 5944 Keyless Entry Module: Service and Repair Program Remote Keyless Entry Module 1. Retrieve the programming line from the upper edge of the passenger side cowl trim panel. The RKE Programming Line is a green wire with a red bullet connector. 2. Using a jumper wire, ground the RKE programming line. 3. Turn ignition switch to the ON position. 4. Press any button on the transmitter to set code. The locks will cycle to confirm programming. If there is a second transmitter it must be set at this time. Press any button on the second transmitter and wait for the locks to cycle to confirm programming. 5. Disconnect the programming line from ground. This returns the system to its normal operation mode. 6. Replace all removed components. Return programming line to its original position. Check for system operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > Rear Bumper Fascia - Production Modifications Bumper: Technical Service Bulletins Rear Bumper Fascia - Production Modifications NO: 23-29-97 GROUP: Body DATE: May 16, 1997 SUBJECT: Tape Across Rear Fascia Fasteners Shows In Opening MODELS: 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT AFTER MAY 9, 1997 (MDH 05-09-XX) AT THE TOLUCA ASSEMBLY PLANT. TOLUCA ASSEMBLY IS DESIGNATED BY A "T" IN THE 11TH POSITION OF THE VEHICLE IDENTIFICATION NUMBER. DISCUSSION: Beginning on May 9, 1997 (MDH 05-09-XX) Toluca Assembly will begin installing a strip of black tape under the fasteners of painted rear fascias to address an assembly process issue (Illustration). The tape will not be applied to fascias molded in color or vehicles built at the Belvidere Assembly Plant. The tape will be applied securely and is intended to last the lifetime of the vehicle. There will be no replacement service tape, if the tape should come loose it should be removed completely and discarded. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Remove door trim panel and water dam. 2. Close door glass. 3. Disconnect lock and latch rods from door latch. Fig. 6 4. Remove nut attaching door handle retainer to outer door panel (Fig. 6). 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. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior - Door Trim Panel Service Procedure Revisions Front Door Panel: Technical Service Bulletins Interior - Door Trim Panel Service Procedure Revisions NUMBER: 26-06-97I GROUP: Miscellaneous DATE: June, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Neon Service Manual - Publication Number 81-370-7025 DESCRIPTION OF CHANGES Revision to the door trim panel service procedures Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior - Door Trim Panel Service Procedure Revisions > Page 5961 23-20 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior - Door Trim Panel Service Procedure Revisions > Page 5962 23-21 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior - Door Trim Panel Service Procedure Revisions > Page 5963 23-22 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door - 2 Door Model Front Door Panel: Service and Repair Front Door - 2 Door Model The content of this article reflects changes called for in TSB 26-06-97. Removal 1. Lower door glass. 2. Remove screw attaching pull cup to door trim panel. 3. Pull inside latch release handle to access attaching screw and remove. 4. Remove window regulator crank, if equipped. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door - 2 Door Model > Page 5966 5. Disengage all hidden push-in fasteners attaching trim panel to door. Ensure that each push-in fastener is disengaged using the removal tool. 6. Tilt trim panel outward to clear locator pins on backside of trim panel. 7. Lift trim panel to disengage from retainer channel on inner belt weatherstrip. 8. Disengage clip holding door latch linkage to back of inside door handle. 9. Separate latch rod from handle. 10. Disengage wire connector from power door lock switch, mirror switch, and power window switch, if equipped. 11. Separate trim panel from vehicle. Installation 1. Replace any damaged or missing push-in fasteners with original equipment push-in fasteners. 2. Place trim panel near door. 3. Engage wire connectors to power lock switch, mirror switch, and power window switch, if equipped. 4. Insert latch rod into inside release handle. 5. Engage clip holding door latch linkage to back of inside door handle. 6. Engage trim panel into retainer channel at top of door and push down to seat. 7. Locate door trim panel to inner door panel by aligning locating pins on backside of trim panel to mating holes in inner door panel. Gently shift panel forward or rearward if necessary. 8. Engage hidden push-in fasteners holding trim panel to door from around perimeter of trim panel. 9. With the window in the down position, orientate the window regulator crank handle appropriately. Install the right handle at the 10 o'clock position and the left handle at the 2 o'clock position, if equipped. 10. Install screw holding trim panel to door behind inside door handle. 11. Install screw inside pull cup holding door trim panel to bracket. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door - 2 Door Model > Page 5967 Front Door Panel: Service and Repair Front Door - 4 Door Model The content of this article reflects changes called for in TSB 26-06-97. Removal 1. Lower door glass. 2. Remove screw attaching pull cup to door trim panel. 3. Pull inside latch release handle to access attaching screw and remove. 4. Remove window regulator crank, if equipped. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door - 2 Door Model > Page 5968 5. Disengage all push-in fasteners attaching trim to door panel. Ensure that each push-in fastener is disengaged using the removal tool. 6. Tilt trim panel outward to clear locator pins on backside of trim panel. 7. Lift trim panel to disengage from retainer channel on inner belt weatherstrip at the top of the door. 8. Disengage clip holding door latch linkage to back of inside door handle. 9. Separate latch rod from handle. 10. Disengage wire connector from power door lock switch, mirror switch, and power window switch, if equipped. 11. Separate trim panel from door. Installation 1. Replace any damaged or missing push-in fasteners with original equipment push-in fasteners. 2. Place trim panel near door. 3. Engage wire connector into power door lock switch, mirror switch, and power window switch, if equipped. 4. Insert latch rod into inside latch release. 5. Engage 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. Engage push-in fasteners to hold trim to door panel around perimeter of trim panel. 8. With the window in the down position, orientate the window regulator crank handle appropriately. Install the right handle at the 10 o'clock position and the left handle at the 2 o'clock position, if equipped. 9. Install screw holding trim panel to door from behind inside latch release handle. 10. Install screw inside pull cup holding door trim panel to bracket. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Remove door trim panel. 2. Close door glass. 3. Disengage clips attaching linkage rods to door handle. Fig. 4 4. Remove nuts attaching outside handle to door (Fig. 4). 5. Remove outside handle. INSTALLATION 1. Position door outside handle in opening. 2. Tighten attaching nuts. 3. Connect linkage rods to latch. 4. Connect lock and latch rods to door handle. 5. Install door trim panel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Release Lever > Component Information > Technical Service Bulletins > Emergency Trunk Release - Availability Trunk / Liftgate Release Lever: Technical Service Bulletins Emergency Trunk Release - Availability NUMBER: 23-02-00 GROUP: Body DATE: Feb. 4, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-20-99 REV. A DATED AUGUST 13, 1999 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS INFORMATION. SUBJECT: Internal Emergency Trunk Release MODELS: 1995 - 2000 (JA) Breeze/Cirrus/Stratus 1996 - 2000 (JX) Sebring Convertible **1993 2000 (LH) Concorde/Intrepid/LHS/New Yorker/Vision/300M** 1995 - 2000 (PL) Neon NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO INSTALL AN INTERNAL EMERGENCY TRUNK RELEASE. RELEASE INSTALLATION EXPENSE IS SHARED BY DAIMLERCHRYSLER AND THE CUSTOMER. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE LABOR ONLY. THE CUSTOMER IS RESPONSIBLE FOR THE PART EXPENSE. REFER TO WARRANTY BULLETIN D-99-20 FOR CLAIMING THE LABOR EXPENSE. DISCUSSION: DaimlerChrysler Corporation is now offering internal emergency trunk releases for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the parts are available. The trunk releases are packaged in a kit containing all necessary parts and a detailed instruction sheet. PARTS REQUIRED: 1 05016812AA Kit, Emergency Trunk Release, 1995 - 2000 JA **1 05016813AA Kit, Emergency Trunk Release, 1993 - 1997 LH** 1 05016810AA Kit, Emergency Trunk Release, 1998 - 2000 LH 1 05016809AA Kit, Emergency Trunk Release, 2000 PL W/Remote Entry 1 05016811AA Kit, Emergency Trunk Release, 1994 - 1999 PL, 2000 PL W/Manual Entry 1 05016814AA Kit, Emergency Trunk Release, 1996 - 2000 JX POLICY: Customer Satisfaction Announcement TIME ALLOWANCE: Labor Operation No. 23-41-25-95 ......................................................................................................................................... .............................. 1.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well - Creak/Rattle on Bumps Technical Service Bulletin # 23-47-97 Date: 970926 Front Foot Well - Creak/Rattle on Bumps NO: 23-47-97 GROUP: Body EFFECTIVE DATE: Sept. 26, 1997 SUBJECT: Creak/Rattle From Front Foot Well MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Creak/rattle from driver or passenger front foot well. The creak/rattle is more pronounced over bumps. DIAGNOSIS: Drive the vehicle over a bumpy road and listen for a creak/rattle in the foot well area. If creak/rattle is heard proceed with the repair procedure on the side that the noise is heard. If the side the creak/rattle is coming from cannot be determined by sound, torque each crossmember bolt to 163 Nm (120 ft lbs). If the bolt was at 163 Nm (120 ft.lbs), the torque is acceptable and no further action is needed on that side. If the torque was not at 163 Nm (120 ft. lbs), proceed to the Repair Procedure. PARTS REQUIRED: AR(1) 05011650AA Crossmember Bolt/Nut Repair Kit (Right) AR(1) 05011651AA Crossmember Bolt/Nut Repair Kit (Left) Each kit will include one of the following components: Cage Nut, Crossmember Bolt, Crossmember Mastic Patch Drain Plug Access Hole Template POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-30-01-90 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves drilling an access hole to replace the crossmember bolt and cage nut, then sealing the access hole. 1. Raise vehicle to gain access to the crossmember bolt. 2. Remove the crossmember bolt. 3. Lower the vehicle and open the door. 4. Slide the seat to the full rearward position. Remove the floor mat if so equipped. 5. Remove the scuff plate and kick panel. 6. Pull the carpet and pad away to access the floor. 7. Prop the clutch and brake pedal to make room for drilling (drivers side only). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well - Creak/Rattle on Bumps > Page 5987 8. Insert the template, mark and center punch the floor pan (Figure 1). 9. Using a drill and 70 mm (2-3/4") Dia hole saw, drill in the floor to access the cage nut. 10. Pry up on the cage surrounding the nut and slide the nut out. 11. Insert the new nut and bend the cage back into position to secure the nut. 12. Raise the vehicle and install the new bolt, torque to 163 Nm (120 ft. lbs.) 13. Lower the vehicle and vacuum all drill shavings. 14. Install the drain hole plug into the hole in the floor. Use a heat gun to seal the plug to the floor. 15. Center the mastic patch over the drain hole plug and install (Figure 2). To install, remove backing paper and apply firm even pressure across the entire patch to seal. 16. Position pad and carpet into proper location. 17. Remove prop holding brake and clutch pedal if applied. 18. Install the scuff plate and kick panel. 19. Install floor mat and reposition seat. 20. Repeat procedure for other side if needed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well - Creak/Rattle on Bumps Technical Service Bulletin # 23-47-97 Date: 970926 Front Foot Well - Creak/Rattle on Bumps NO: 23-47-97 GROUP: Body EFFECTIVE DATE: Sept. 26, 1997 SUBJECT: Creak/Rattle From Front Foot Well MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Creak/rattle from driver or passenger front foot well. The creak/rattle is more pronounced over bumps. DIAGNOSIS: Drive the vehicle over a bumpy road and listen for a creak/rattle in the foot well area. If creak/rattle is heard proceed with the repair procedure on the side that the noise is heard. If the side the creak/rattle is coming from cannot be determined by sound, torque each crossmember bolt to 163 Nm (120 ft lbs). If the bolt was at 163 Nm (120 ft.lbs), the torque is acceptable and no further action is needed on that side. If the torque was not at 163 Nm (120 ft. lbs), proceed to the Repair Procedure. PARTS REQUIRED: AR(1) 05011650AA Crossmember Bolt/Nut Repair Kit (Right) AR(1) 05011651AA Crossmember Bolt/Nut Repair Kit (Left) Each kit will include one of the following components: Cage Nut, Crossmember Bolt, Crossmember Mastic Patch Drain Plug Access Hole Template POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-30-01-90 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves drilling an access hole to replace the crossmember bolt and cage nut, then sealing the access hole. 1. Raise vehicle to gain access to the crossmember bolt. 2. Remove the crossmember bolt. 3. Lower the vehicle and open the door. 4. Slide the seat to the full rearward position. Remove the floor mat if so equipped. 5. Remove the scuff plate and kick panel. 6. Pull the carpet and pad away to access the floor. 7. Prop the clutch and brake pedal to make room for drilling (drivers side only). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well - Creak/Rattle on Bumps > Page 5993 8. Insert the template, mark and center punch the floor pan (Figure 1). 9. Using a drill and 70 mm (2-3/4") Dia hole saw, drill in the floor to access the cage nut. 10. Pry up on the cage surrounding the nut and slide the nut out. 11. Insert the new nut and bend the cage back into position to secure the nut. 12. Raise the vehicle and install the new bolt, torque to 163 Nm (120 ft. lbs.) 13. Lower the vehicle and vacuum all drill shavings. 14. Install the drain hole plug into the hole in the floor. Use a heat gun to seal the plug to the floor. 15. Center the mastic patch over the drain hole plug and install (Figure 2). To install, remove backing paper and apply firm even pressure across the entire patch to seal. 16. Position pad and carpet into proper location. 17. Remove prop holding brake and clutch pedal if applied. 18. Install the scuff plate and kick panel. 19. Install floor mat and reposition seat. 20. Repeat procedure for other side if needed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Page 5994 Cross-Member: Specifications Attaching Bolts ..................................................................................................................................... ................................................ 163 Nm (120 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 232497 > May > 97 > Center Console Latch - Broken Console: Customer Interest Center Console Latch - Broken NO: 23-24-97 GROUP: Body EFFECTIVE DATE: May 23, 1997 SUBJECT: Broken Center Console Latch MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Center console latch broken. DISCUSSION: If the center console latch (P/N 04775112AB) is broken, only the latch should be replaced without replacing the console lid. Illustration PARTS REQUIRED: 1 04775112AB Latch, Center Console REPAIR PROCEDURE: This bulletin involves replacing the center console latch. 1. Lift the center console lid. 2. Remove the two screws holding the latch to the lid and remove latch. 3. Install the new center console latch (P/N 04775112AB) and torque the two screws to 1.7 Nm (15 in.-lbs.) POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-41-40-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 232497 > May > 97 > Center Console Latch - Broken Console: All Technical Service Bulletins Center Console Latch - Broken NO: 23-24-97 GROUP: Body EFFECTIVE DATE: May 23, 1997 SUBJECT: Broken Center Console Latch MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Center console latch broken. DISCUSSION: If the center console latch (P/N 04775112AB) is broken, only the latch should be replaced without replacing the console lid. Illustration PARTS REQUIRED: 1 04775112AB Latch, Center Console REPAIR PROCEDURE: This bulletin involves replacing the center console latch. 1. Lift the center console lid. 2. Remove the two screws holding the latch to the lid and remove latch. 3. Install the new center console latch (P/N 04775112AB) and torque the two screws to 1.7 Nm (15 in.-lbs.) POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-41-40-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Page 6009 Console: Service and Repair REMOVAL 1. Remove the MTX shifter knob only. 2. Remove the attaching screws from each side of the cup holder. Floor Console With Transmission Range Indicator a. Non-armrest console. Remove the two screws from the rear of the console. b. Armrest console. Remove the four screws in the console bin. 3. Pull the parking brake lever up all the way 4. Lift the console at the rear and guide it out from under the instrument panel. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components . Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 6015 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming 1. Verify that the negative battery cable is disconnected and isolated. 2. Connect scan tool (DRB) to Data Link connector, located at right side of the steering column and at the lower edge of the lower instrument panel. 3. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 4. After checking that no one is inside the vehicle, connect the battery negative terminal. 5. Using the scan tool, read and record active diagnostic code data. 6. Read and record any stored diagnostic codes. 7. Refer to the airbag system Diagnostic Test if any diagnostic codes are found in Step 5 or Step 6. 8. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the airbag system Diagnostic Test. If the airbag warning lamp either fails to light with the ignition switch ON, or the light goes on and stays on, there is a system malfunction. Refer to the airbag system Diagnostic Test. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair Glove Compartment: Service and Repair REMOVAL 1. Disconnect battery negative cable and isolate it or remove fuse 12 prior to removing the switch, or the wires may short to ground. 2. Remove the screws along the bottom of glove box door. 3. Open the glove box and push the glove box sides inward allowing the door bumpers to clear and box to tip forward. 4. Pull the glove box door/bin rearward and remove from vehicle. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Replacement Keyless Entry Module: Service and Repair Replacement REMOVAL 1. Remove the right trim panel. 2. Disconnect wire connector from RKE module. RKE Module Location 3. Remove screws holding RKE module to instrument panel assembly. 4. Remove module. INSTALLATION - For installation, reverse above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Replacement > Page 6025 Keyless Entry Module: Service and Repair Program Remote Keyless Entry Module 1. Retrieve the programming line from the upper edge of the passenger side cowl trim panel. The RKE Programming Line is a green wire with a red bullet connector. 2. Using a jumper wire, ground the RKE programming line. 3. Turn ignition switch to the ON position. 4. Press any button on the transmitter to set code. The locks will cycle to confirm programming. If there is a second transmitter it must be set at this time. Press any button on the second transmitter and wait for the locks to cycle to confirm programming. 5. Disconnect the programming line from ground. This returns the system to its normal operation mode. 6. Replace all removed components. Return programming line to its original position. Check for system operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Programming Connector > Component Information > Locations Keyless Entry Programming Connector: Locations Retrieve the programming line from the upper edge of the passenger side cowl trim panel. The RKE Programming Line is a GREEN wire with a RED BULLET CONNECTOR. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure Keyless Entry Transmitter Battery: Customer Interest RKE Transmitter - Premature Battery Failure NO: 08-39-97 GROUP: Electrical DATE: Nov. 28, 1997 SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely MODELS: 1997 - 1998 (AB) Ram Van/Wagon 1997 - 1998 (AN) Dakota/Dakota Cab & Chassis 1998 (BRIBE)Ram Truck 1998 (DN) Durango 1997 (LH) Concorde/Intrepid/LHS/Vision 1997 - 1998 (NS) Town & Country/Caravan/Voyager 1997 - 1998 (PL) Neon 1997 (PR) Prowler 1997 - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX). SYMPTOM/CONDITION: Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH 0815XX, perform the Repair Procedure. PARTS REQUIRED: AR 04686366 Transmitter, RKE- NS, PL & PR AR 04759136AB Transmitter, RKE- LH AR 56007049 Transmitter, RKE- AB & 1997 AN AR 56008761 Transmitter 1, RKE- ZJ & DN AR 56008762 Transmitter 2, RKE- ZJ AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN REPAIR PROCEDURE: This bulletin involves replacing the RKE transmitter(s). 1. Replace RKE transmitter(s) that have discharged batteries. 2. Program the RKE transmitter(s) to the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-28-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure Keyless Entry Transmitter Battery: All Technical Service Bulletins RKE Transmitter - Premature Battery Failure NO: 08-39-97 GROUP: Electrical DATE: Nov. 28, 1997 SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely MODELS: 1997 - 1998 (AB) Ram Van/Wagon 1997 - 1998 (AN) Dakota/Dakota Cab & Chassis 1998 (BRIBE)Ram Truck 1998 (DN) Durango 1997 (LH) Concorde/Intrepid/LHS/Vision 1997 - 1998 (NS) Town & Country/Caravan/Voyager 1997 - 1998 (PL) Neon 1997 (PR) Prowler 1997 - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX). SYMPTOM/CONDITION: Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH 0815XX, perform the Repair Procedure. PARTS REQUIRED: AR 04686366 Transmitter, RKE- NS, PL & PR AR 04759136AB Transmitter, RKE- LH AR 56007049 Transmitter, RKE- AB & 1997 AN AR 56008761 Transmitter 1, RKE- ZJ & DN AR 56008762 Transmitter 2, RKE- ZJ AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN REPAIR PROCEDURE: This bulletin involves replacing the RKE transmitter(s). 1. Replace RKE transmitter(s) that have discharged batteries. 2. Program the RKE transmitter(s) to the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-28-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation Power Door Lock Actuator: Description and Operation SYSTEM OPERATION Make certain battery is in normal condition before circuits are tested. To determine which motor is faulty, check each individual door for electrical lock and unlock or disconnect the motor connectors one at a time, while operating the door lock switch. In the event that none of the motors work, the problem maybe caused by a shorted motor, or a bad switch. Disconnecting the defective motor will allow the others to work. Door Latch Assembly To test an individual door lock motor, disconnect the electrical connector from the motor. To lock the door, connect a 12 Volt power source to the positive pin of the lock motor and a ground wire to the other pin To unlock the door reverse the wire connections at the motor pin terminals. If these results are NOT obtained, replace the door latch assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation > Page 6047 Power Door Lock Actuator: Service and Repair REMOVAL 1. Remove door trim panel. Door Latch Assembly 2. Disconnect all door linkages at the latch/lock assembly. 3. Disconnect motor wire connector. 4. Remove latch/lock assembly attaching screws and remove assembly. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Description and Operation Power Door Lock Switch: Description and Operation CIRCUIT OPERATION Left Door Switch Operation (Lock) When the door lock switch is moved to the LOCK position, voltage is supplied on the P35 circuit to the bus bar located inside the right door switch, lock side. Battery voltage is passed through the switch to the P33 circuit to the door motors. Grounding is provided through the P34 circuit for all door motors back to the right door switch. The ground is passed through the bus bar internal to the switch, UNLOCK side, to the P36 circuit. The P36 circuit connects to the left front switch to a bus bar, internal to the switch, and then to the Z8 circuit. The Z8 circuit connects to its grounding point. Left Door Switch Operation (Unlock) When the switch is moved to the UNLOCK position, voltage is supplied on the P36 circuit to the right door switch, unlock side. The battery voltage is passed through the switch internal bus bar to the P34 circuit. The P34 circuit then connects to the door motors on the unlock side. Grounding for the UNLOCK function is provided by the P33 circuit. The P33 circuit connects back to the right door switch, LOCK side, and passes through the internal bus bar to the P35 circuit. The P35 circuit connects back to the left door switch, and passes through the switch to the Z8 circuit. The Z8 circuit goes to it's grounding point. Right Door Switch Operation (Lock) When the switch is moved to the LOCK position, voltage is supplied to the P33 circuit, and then to the door lock motors. The ground path is provided on the P34 circuit back to the right door switch. The ground is passed through the switch internal bus bar to the P36 circuit. The P36 circuit connects to the left door switch and through to the Z8 circuit. The Z8 circuit then connects to the grounding point at the left center instrument panel support. Right Door Switch Operation (Unlock) When the switch is moved to the UNLOCK position voltage is supplied to the P34 circuit from the switch to the door UNLOCK side of the motors. The grounding path is through the LOCK side of the motors, circuit P33, back to the switch. The ground continues through the internal bus bar of the switch on circuit P35 to the left door switch. At the left door switch, the ground passes through that switches internal bus bar to the Z8 grounding point. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Description and Operation > Page 6051 Power Door Lock Switch: Testing and Inspection Door Lock Switch Continuity Test Remove the switch from its mounting location. Using an ohmmeter, refer to the Door Lock Switch Continuity Test to determine if continuity is correct in the Lock and Unlock switch positions. If these results are not obtained, replace the switch. Wiring The following wiring test sequence determines whether or not voltage is continuous through the body harness to switch. 1. Remove left side switch from door trim panel. 2. Carefully separate multiple terminal block on wiring harness from switch body. 3. Connect one lead of test light to a ground terminal. Touch other test light lead to Red Wire terminal. a. If test light comes on, the wiring circuit between the battery and switch is functional. b. If test light does not come on, check fuse 3 in the fuse block or for a open circuit. 4. If test light comes on, the wiring circuit between the battery and switch is functional. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Description and Operation > Page 6052 Power Door Lock Switch: Service and Repair REMOVAL 1. Remove front door trim. 2. Disconnect wire connector. 3. Remove attaching screws. 4. Remove the switch. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Testing and Inspection Power Mirror Motor: Testing and Inspection 1. Remove door trim panel. 2. Remove switch mounting screws from back side of trim panel and remove switch. 3. Disconnect wire connector. Mirror Test Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Testing and Inspection > Page 6057 Power Fold Away Mirror Test 4. Using two jumper wires, one connected to a 12 volt source, and 2 the other connected to a good body ground. Refer to the Mirror Test for appropriate mirror response. RHD vehicle with Power Fold Away Mirror, refer to Power Fold Away Mirror Switch Test Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Testing and Inspection > Page 6058 Power Fold Away Mirrors Wiring Schematic 5. If test results are not obtained as shown, check for open or shorted circuit, or replace mirror assembly as necessary. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Description and Operation Power Mirror Switch: Description and Operation CIRCUIT OPERATION The power mirror switch has a right and left position. Moving the switch to either of these positions changes the voltage path internal to the switch (i.e.. changes polarity at the motors). When the switch is moved to the left position and mirror movement UP is selected, voltage is supplied through the P93 circuit and the ground path is through circuit P90. When the DOWN movement is selected the power and ground are reversed. If a left door mirror movement LEFT is selected voltage is supplied through the P95 circuit and the ground is passed through circuit P91. When the left door minor RIGHT movement is selected the power and ground are reversed. When the switch is moved to the right position and mirror movement UP is selected, voltage is supplied through the P92 circuit and the ground path is through circuit P90. When the DOWN movement is selected the power and ground are reversed. If a right door mirror movement LEFT is selected voltage is supplied through the P94 circuit and the ground is passed through circuit P91. When the left door mirror RIGHT movement is selected the power and ground are reversed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Description and Operation > Page 6062 Power Mirror Switch: Testing and Inspection Mirror Switch Test Mirror Switch Test 1. Remove power mirror switch from mounting position. 2. Disconnect wiring harness at switch connector. 3. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror Switch Test and RHD Power Fold Away Mirror Switch Test. 4. If test results are not obtained as shown, replace the switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Description and Operation > Page 6063 Power Mirror Switch: Service and Repair REMOVAL 1. Remove door trim panel. 2. Remove switch mounting screws from back side of trim panel and remove switch. 3. Disconnect wire connector. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 23-25-00 > Jun > 00 > Paint - Surface Fogging or Whitening Paint: Customer Interest Paint - Surface Fogging or Whitening NUMBER: 23-25-00 GROUP: Body DATE: Jun. 30, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-05-98, DATED JANUARY 30, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Paint Fogging/Whitening OVERVIEW: This bulletin involves removal of a fogging or staining condition from any painted surface where moisture may be trapped under the clear coat. MODELS: 1996 - **2000** (JX) Sebring Convertible 1995 - **2000** (PL) Neon **2001 (PT) PT Cruiser** 1997 - **2001** (BR) Ram Truck SYMPTOM/CONDITION: Painted surfaces of the vehicle that are covered for extended periods of time with front end covers (Bras), transit films or magnetic signs may appear to have a white "milky" spot ** on dark colors, or a fogging, coffee colored spot lighter colors**. NOTE: WHEN USING A FRONT END COVER OR MAGNETIC SIGN, FOLLOW THE MANUFACTURER'S PRECAUTIONS. DIAGNOSIS: **Wash the affected area(s) with mild soap and water. Spot clean any area(s) to remove any difficult dirt, tar, bugs, etc. If paint fogging/whitening exist, run your hand over the surface, if no surface condition exists perform the following Repair Procedure**. EQUIPMENT REQUIRED **Heat Gun** REPAIR PROCEDURE: 1. **Place a heat gun approximately 100 to 150 mm (4 to 6 inches) from the effected area. A target surface temperature of 80° to 95° C. (180° to 200 °F.) is preferred. NOTE: DO NOT APPLY HEAT ABOVE 95° C. (200°F.) TO ANY PLASTIC PARTS. 2. Heat the effected area for approximately 2 to 4 minutes. The amount of time is dependent upon the size and shape of the affected area and the severity of the condition. NOTE: CIRCULATE THE HEAT GUN AROUND THE EFFECTED AREA. DO NOT ALLOW HEAT TO BE DIRECTED AT ONE AREA FOR TOO LONG, PAINT DAMAGE MAY OCCUR. 3. If this Repair Procedure does not correct the condition, color-coat paint repair will be required. NOTE: IF PAINT "FOGGING" DAMAGE WAS CAUSED BY A FRONT END COVER OR A MAGNETIC SIGN, THE OWNER SHOULD BE CAUTIONED AGAINST USING THAT PRODUCT, OR A SIMILAR PRODUCT THAT MAY CREATE THE PAINT "FOGGING".** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 23-25-00 > Jun > 00 > Paint - Surface Fogging or Whitening > Page 6073 Labor Operation No: 23-60-02-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-25-00 > Jun > 00 > Paint - Surface Fogging or Whitening Paint: All Technical Service Bulletins Paint - Surface Fogging or Whitening NUMBER: 23-25-00 GROUP: Body DATE: Jun. 30, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-05-98, DATED JANUARY 30, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Paint Fogging/Whitening OVERVIEW: This bulletin involves removal of a fogging or staining condition from any painted surface where moisture may be trapped under the clear coat. MODELS: 1996 - **2000** (JX) Sebring Convertible 1995 - **2000** (PL) Neon **2001 (PT) PT Cruiser** 1997 - **2001** (BR) Ram Truck SYMPTOM/CONDITION: Painted surfaces of the vehicle that are covered for extended periods of time with front end covers (Bras), transit films or magnetic signs may appear to have a white "milky" spot ** on dark colors, or a fogging, coffee colored spot lighter colors**. NOTE: WHEN USING A FRONT END COVER OR MAGNETIC SIGN, FOLLOW THE MANUFACTURER'S PRECAUTIONS. DIAGNOSIS: **Wash the affected area(s) with mild soap and water. Spot clean any area(s) to remove any difficult dirt, tar, bugs, etc. If paint fogging/whitening exist, run your hand over the surface, if no surface condition exists perform the following Repair Procedure**. EQUIPMENT REQUIRED **Heat Gun** REPAIR PROCEDURE: 1. **Place a heat gun approximately 100 to 150 mm (4 to 6 inches) from the effected area. A target surface temperature of 80° to 95° C. (180° to 200 °F.) is preferred. NOTE: DO NOT APPLY HEAT ABOVE 95° C. (200°F.) TO ANY PLASTIC PARTS. 2. Heat the effected area for approximately 2 to 4 minutes. The amount of time is dependent upon the size and shape of the affected area and the severity of the condition. NOTE: CIRCULATE THE HEAT GUN AROUND THE EFFECTED AREA. DO NOT ALLOW HEAT TO BE DIRECTED AT ONE AREA FOR TOO LONG, PAINT DAMAGE MAY OCCUR. 3. If this Repair Procedure does not correct the condition, color-coat paint repair will be required. NOTE: IF PAINT "FOGGING" DAMAGE WAS CAUSED BY A FRONT END COVER OR A MAGNETIC SIGN, THE OWNER SHOULD BE CAUTIONED AGAINST USING THAT PRODUCT, OR A SIMILAR PRODUCT THAT MAY CREATE THE PAINT "FOGGING".** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-25-00 > Jun > 00 > Paint - Surface Fogging or Whitening > Page 6079 Labor Operation No: 23-60-02-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 236996 > Nov > 96 > Paint - Fallout Damage Repair Paint: All Technical Service Bulletins Paint - Fallout Damage Repair NO: 23-69-96 GROUP: Body DATE: Nov. 22, 1996 SUBJECT: Repair Of Fallout Damaged Paint MODELS: 1997 (AB) Ram Van/Wagon 1997 (AN) Dakota 1997 (BR) Ram Pickup 1997 (FJ) Sebring/Avenger/Talon 1997 (GS) Chrysler Voyager (International Market) 1997 (JA) Cirrus/Stratus/Breeze 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1997 (NS) Town & Country/Caravan/Voyager 1997 (PL) Neon 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1997 (XJ) Cherokee 1997 (ZG) Grand Cherokee (International Market) 1997 (ZJ) Grand Cherokee NOTE: THE MOPAR FALLOUT REMOVAL KIT CAN BE USED ON ANY CURRENT OR PAST MODEL YEAR CHRYSLER VEHICLE. DISCUSSION: Mopar Parts has released a new product, Mopar Fallout Removal Kit (p/n 04882417) for correcting paint damage due to industrial fallout, rail dust, over-spray and volcanic ash. The Mopar Fallout Removal Kit does not use a compounding process or acid wash and is the current Chrysler preferred method for correcting fallout damage. This product uses a clay polymer material and a liquid that are safer and better than other fallout removal methods. The Mopar Fallout Removal Kit is easier to use and less expensive than other methods. Some vehicles that would have been repainted in the past have been saved from that time consuming and expensive process with the Mopar Fallout Removal Kit. NOTE: WHEN ALL OF THE FALLOUT REPAIR LIQUID HAS BEEN USED, DISCARD THE CLAY POLYMER MATERIAL. CONTINUED USE OF THE CLAY POLYMER AFTER ALL OF THE FALLOUT REPAIR LIQUID HAS BEEN USED CAN CAUSE MINOR SCRATCHING OF THE PAINT FINISH. THE AMOUNT OF FALLOUT REPAIR LIQUID PROVIDED IN THE KIT WAS ESTABLISHED BY DETERMINING THE AMOUNT OF FALLOUT THE CLAY POLYMER COULD ABSORB BEFORE IT BECAME OVER SATURATED WITH FALLOUT AND WOULD CAUSE DAMAGE TO THE PAINT FINISH. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 236996 > Nov > 96 > Paint - Fallout Damage Repair Paint: All Technical Service Bulletins Paint - Fallout Damage Repair NO: 23-69-96 GROUP: Body DATE: Nov. 22, 1996 SUBJECT: Repair Of Fallout Damaged Paint MODELS: 1997 (AB) Ram Van/Wagon 1997 (AN) Dakota 1997 (BR) Ram Pickup 1997 (FJ) Sebring/Avenger/Talon 1997 (GS) Chrysler Voyager (International Market) 1997 (JA) Cirrus/Stratus/Breeze 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1997 (NS) Town & Country/Caravan/Voyager 1997 (PL) Neon 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1997 (XJ) Cherokee 1997 (ZG) Grand Cherokee (International Market) 1997 (ZJ) Grand Cherokee NOTE: THE MOPAR FALLOUT REMOVAL KIT CAN BE USED ON ANY CURRENT OR PAST MODEL YEAR CHRYSLER VEHICLE. DISCUSSION: Mopar Parts has released a new product, Mopar Fallout Removal Kit (p/n 04882417) for correcting paint damage due to industrial fallout, rail dust, over-spray and volcanic ash. The Mopar Fallout Removal Kit does not use a compounding process or acid wash and is the current Chrysler preferred method for correcting fallout damage. This product uses a clay polymer material and a liquid that are safer and better than other fallout removal methods. The Mopar Fallout Removal Kit is easier to use and less expensive than other methods. Some vehicles that would have been repainted in the past have been saved from that time consuming and expensive process with the Mopar Fallout Removal Kit. NOTE: WHEN ALL OF THE FALLOUT REPAIR LIQUID HAS BEEN USED, DISCARD THE CLAY POLYMER MATERIAL. CONTINUED USE OF THE CLAY POLYMER AFTER ALL OF THE FALLOUT REPAIR LIQUID HAS BEEN USED CAN CAUSE MINOR SCRATCHING OF THE PAINT FINISH. THE AMOUNT OF FALLOUT REPAIR LIQUID PROVIDED IN THE KIT WAS ESTABLISHED BY DETERMINING THE AMOUNT OF FALLOUT THE CLAY POLYMER COULD ABSORB BEFORE IT BECAME OVER SATURATED WITH FALLOUT AND WOULD CAUSE DAMAGE TO THE PAINT FINISH. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 6089 Paint: By Symptom Technical Service Bulletin # 23-25-00 Date: 000630 Paint - Surface Fogging or Whitening NUMBER: 23-25-00 GROUP: Body DATE: Jun. 30, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-05-98, DATED JANUARY 30, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Paint Fogging/Whitening OVERVIEW: This bulletin involves removal of a fogging or staining condition from any painted surface where moisture may be trapped under the clear coat. MODELS: 1996 - **2000** (JX) Sebring Convertible 1995 - **2000** (PL) Neon **2001 (PT) PT Cruiser** 1997 - **2001** (BR) Ram Truck SYMPTOM/CONDITION: Painted surfaces of the vehicle that are covered for extended periods of time with front end covers (Bras), transit films or magnetic signs may appear to have a white "milky" spot ** on dark colors, or a fogging, coffee colored spot lighter colors**. NOTE: WHEN USING A FRONT END COVER OR MAGNETIC SIGN, FOLLOW THE MANUFACTURER'S PRECAUTIONS. DIAGNOSIS: **Wash the affected area(s) with mild soap and water. Spot clean any area(s) to remove any difficult dirt, tar, bugs, etc. If paint fogging/whitening exist, run your hand over the surface, if no surface condition exists perform the following Repair Procedure**. EQUIPMENT REQUIRED **Heat Gun** REPAIR PROCEDURE: 1. **Place a heat gun approximately 100 to 150 mm (4 to 6 inches) from the effected area. A target surface temperature of 80° to 95° C. (180° to 200 °F.) is preferred. NOTE: DO NOT APPLY HEAT ABOVE 95° C. (200°F.) TO ANY PLASTIC PARTS. 2. Heat the effected area for approximately 2 to 4 minutes. The amount of time is dependent upon the size and shape of the affected area and the severity of the condition. NOTE: CIRCULATE THE HEAT GUN AROUND THE EFFECTED AREA. DO NOT ALLOW HEAT TO BE DIRECTED AT ONE AREA FOR TOO LONG, PAINT DAMAGE MAY OCCUR. 3. If this Repair Procedure does not correct the condition, color-coat paint repair will be required. NOTE: IF PAINT "FOGGING" DAMAGE WAS CAUSED BY A FRONT END COVER OR A MAGNETIC SIGN, THE OWNER SHOULD BE CAUTIONED AGAINST USING THAT PRODUCT, OR A SIMILAR PRODUCT THAT MAY CREATE THE PAINT "FOGGING".** POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 6090 TIME ALLOWANCE: Labor Operation No: 23-60-02-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Technical Service Bulletin # 23-25-00 Date: 000630 Paint - Surface Fogging or Whitening NUMBER: 23-25-00 GROUP: Body DATE: Jun. 30, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-05-98, DATED JANUARY 30, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Paint Fogging/Whitening OVERVIEW: This bulletin involves removal of a fogging or staining condition from any painted surface where moisture may be trapped under the clear coat. MODELS: 1996 - **2000** (JX) Sebring Convertible 1995 - **2000** (PL) Neon **2001 (PT) PT Cruiser** 1997 - **2001** (BR) Ram Truck SYMPTOM/CONDITION: Painted surfaces of the vehicle that are covered for extended periods of time with front end covers (Bras), transit films or magnetic signs may appear to have a white "milky" spot ** on dark colors, or a fogging, coffee colored spot lighter colors**. NOTE: WHEN USING A FRONT END COVER OR MAGNETIC SIGN, FOLLOW THE MANUFACTURER'S PRECAUTIONS. DIAGNOSIS: **Wash the affected area(s) with mild soap and water. Spot clean any area(s) to remove any difficult dirt, tar, bugs, etc. If paint fogging/whitening exist, run your hand over the surface, if no surface condition exists perform the following Repair Procedure**. EQUIPMENT REQUIRED **Heat Gun** REPAIR PROCEDURE: 1. **Place a heat gun approximately 100 to 150 mm (4 to 6 inches) from the effected area. A target surface temperature of 80° to 95° C. (180° to 200 °F.) is preferred. NOTE: DO NOT APPLY HEAT ABOVE 95° C. (200°F.) TO ANY PLASTIC PARTS. 2. Heat the effected area for approximately 2 to 4 minutes. The amount of time is dependent upon the size and shape of the affected area and the severity of the condition. NOTE: CIRCULATE THE HEAT GUN AROUND THE EFFECTED AREA. DO NOT ALLOW HEAT TO BE DIRECTED AT ONE AREA FOR TOO LONG, PAINT DAMAGE MAY OCCUR. 3. If this Repair Procedure does not correct the condition, color-coat paint repair will be required. NOTE: IF PAINT "FOGGING" DAMAGE WAS CAUSED BY A FRONT END COVER OR A MAGNETIC SIGN, THE OWNER SHOULD BE Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 6091 CAUTIONED AGAINST USING THAT PRODUCT, OR A SIMILAR PRODUCT THAT MAY CREATE THE PAINT "FOGGING".** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-60-02-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Replacement Keyless Entry Module: Service and Repair Replacement REMOVAL 1. Remove the right trim panel. 2. Disconnect wire connector from RKE module. RKE Module Location 3. Remove screws holding RKE module to instrument panel assembly. 4. Remove module. INSTALLATION - For installation, reverse above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Replacement > Page 6097 Keyless Entry Module: Service and Repair Program Remote Keyless Entry Module 1. Retrieve the programming line from the upper edge of the passenger side cowl trim panel. The RKE Programming Line is a green wire with a red bullet connector. 2. Using a jumper wire, ground the RKE programming line. 3. Turn ignition switch to the ON position. 4. Press any button on the transmitter to set code. The locks will cycle to confirm programming. If there is a second transmitter it must be set at this time. Press any button on the second transmitter and wait for the locks to cycle to confirm programming. 5. Disconnect the programming line from ground. This returns the system to its normal operation mode. 6. Replace all removed components. Return programming line to its original position. Check for system operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Technical Service Bulletins > Customer Interest: > 23-46-98 > Oct > 98 > Sunroof Shade - Rattles In Full Open Position Technical Service Bulletin # 23-46-98 Date: 981009 Sunroof Shade - Rattles In Full Open Position NO: 23-46-98 GROUP: Body DATE: Oct. 9, 1998 SUBJECT: Sunroof Sun Shade Rattles In Full Open Position MODELS: 1997-1998 (PL) Neon SYMPTOM/CONDITION The sunroof sun shade rattles in the full open position due to the roof deadner pad not fully bonding to the roof and/or the track foam/sponge bumpers are coming loose from the track. DIAGNOSIS: Open the sun shade to the full open position. Drive the vehicle and listen for a rattle coming from the sun shade/roof area. If the rattle is heard perform the Repair Procedure. PARTS REQUIRED: AR (1) 4546820 Deadner Pad, Roof Panel AR (1) 05027248AA Bumper, Sunroof Rear Track Pad - Right AR (1) 05027249AA Bumper, Sunroof Rear Track Pad - Left NOTE: THE SUNROOF REAR TRACK BUMPERS MUST BE REPLACED AS A SET. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-10-30-93 1.0 Hrs. Sunshade, Sunroof - Repair - 2 Door Vehicles 23-10-30-94 1.1 Hrs. Sunshade, Sunroof - Repair - 4 Door Vehicles FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves reapplying or replacing the existing deadner pad and/or replacing the rear track pad bumpers as needed. 1. Remove the headlining following the procedure in the 1998 Neon Service Manual (Publication No. 81-270-8025) beginning on page 23-19. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Technical Service Bulletins > Customer Interest: > 23-46-98 > Oct > 98 > Sunroof Shade - Rattles In Full Open Position > Page 6108 2. With the headlining removed the deadner pad will be visible (Figure 1). Inspect the large deadner pad and the two C-pillar pads. If the deadner pad is completely disengaged, from the roof it must be replaced, proceed to Step 3. If the deadner pad is loose or partially detached it can be reattached following the procedure beginning with Step 4 (Figure 1). 3. Position the new deadner pad as shown in (Figure 1). 4. Use a six inch roller to pressurize and apply the deadner pad. A constant uniform force should be used to apply the pressure across the complete surface of the deadner pad. 5. Use the six inch roller to firmly seat the C-pillar pads. 6. Inspect the rear track bumpers, if they are loose or missing they must be replaced. 7. Remove the loose bumper or locate the bumper that has fallen off and discard. 8. Clean the surface with isopropyl alcohol and let dry. 9. Remove the backing paper from the new bumper and apply to the same location that the old bumper was removed from (Figure 1). Repeat the procedure for the other side. 10. Install the headlining following the procedure in the 1998 Neon Service Manual (Publication No. 81-270-8025) on page 23-20. Insure that the door weatherstrips are properly seated around the headlining. 11. Verity proper operation of the sunroof and confirm that rattle has been eliminated. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-48-97A > Sep > 97 > Roof Rail Weatherstrip - Water Leaks into Vehicle Weatherstrip: All Technical Service Bulletins Roof Rail Weatherstrip - Water Leaks into Vehicle NO: 23-48-97 Rev. A GROUP: Body DATE: Sep. 19, 1997 SUBJECT: Water Drips From Roof Rail Weatherstrip Channel Into Vehicle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-48-97, DATED AUG. 29, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE PART NUMBERS HAVE BEEN REVISED AND ARE MARKED WITH **ASTERISKS**. MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Water drips from roof rail weatherstrip and retainer channel into vehicle with the door/window open. DISCUSSION: A new anti-drip roof rail retainer channel is available for Sedan and Coupe models. The left and right side roof rail retainer channels must be replaced as a set on 1997 and earlier models due to appearance differences from the existing roof rail retainer channels. PARTS REQUIRED: 1 04724516AA Retainer Channel Assy., Right Front Pillar to Roof Glass Weather Strip, Coupe 1 04724517AA Retainer Channel Assy., Left Front Pillar to Roof Glass Weather Strip, Coupe **1 04724514AA Retainer Channel Assy., Right A to C Pillar Door Glass, Sedan** **1 04724515AA Retainer Channel Assy., Left A to C Pillar Door Glass, Sedan ** 1 04546838 Applique, "B" Pillar, Right 1 04546839 Applique, "B" Pillar, Left REPAIR PROCEDURE: This bulletin involves the replacement of both roof rail retainer channels and B pillar appliques. 1. Open door(s). 2. Using trim stick disengage the top and bottom push in fasteners from "B" pillar applique. Gently pull outward on the applique to remove from the vehicle. NOTE: THE APPLIQUE IS ATTACHED TO THE VEHICLE WITH TWO SIDED TAPE BETWEEN THE PUSH IN FASTENERS, INSURE ALL OF THE OLD TWO SIDED TAPE IS REMOVED FROM THE VEHICLE SURFACE BEFORE INSTALLATION OF NEW PART. 3. Remove the weatherstrip from the retainer channel. 4. Remove the retainer channel from the body side aperture. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-48-97A > Sep > 97 > Roof Rail Weatherstrip - Water Leaks into Vehicle > Page 6114 5. Install the new retainer channel, by inserting the push pin(s). Install the remaining screws and torque to 4.9 Nm (44 in. lbs), Figure 1 - Two Door, Figure 2 - Four Door. 6. Install the weatherstrip into the retainer channel. 7. Remove the backing paper from the "B" pillar two sided tape. Place the "B" pillar applique up to the vehicle and push in the two fasteners. Beginning at the top of the "B" pillar, use firm pressure to completely seat the applique. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-02-15-92 2 Door 0.9 Hrs. 23-02-15-93 4 Door 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sun Shade: > 23-48-97A > Sep > 97 > Customer Interest for Sun Shade: > 23-46-98 > Oct > 98 > Sunroof Shade - Rattles In Full Open Position Technical Service Bulletin # 23-46-98 Date: 981009 Sunroof Shade - Rattles In Full Open Position NO: 23-46-98 GROUP: Body DATE: Oct. 9, 1998 SUBJECT: Sunroof Sun Shade Rattles In Full Open Position MODELS: 1997-1998 (PL) Neon SYMPTOM/CONDITION The sunroof sun shade rattles in the full open position due to the roof deadner pad not fully bonding to the roof and/or the track foam/sponge bumpers are coming loose from the track. DIAGNOSIS: Open the sun shade to the full open position. Drive the vehicle and listen for a rattle coming from the sun shade/roof area. If the rattle is heard perform the Repair Procedure. PARTS REQUIRED: AR (1) 4546820 Deadner Pad, Roof Panel AR (1) 05027248AA Bumper, Sunroof Rear Track Pad - Right AR (1) 05027249AA Bumper, Sunroof Rear Track Pad - Left NOTE: THE SUNROOF REAR TRACK BUMPERS MUST BE REPLACED AS A SET. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-10-30-93 1.0 Hrs. Sunshade, Sunroof - Repair - 2 Door Vehicles 23-10-30-94 1.1 Hrs. Sunshade, Sunroof - Repair - 4 Door Vehicles FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves reapplying or replacing the existing deadner pad and/or replacing the rear track pad bumpers as needed. 1. Remove the headlining following the procedure in the 1998 Neon Service Manual (Publication No. 81-270-8025) beginning on page 23-19. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sun Shade: > 23-48-97A > Sep > 97 > Customer Interest for Sun Shade: > 23-46-98 > Oct > 98 > Sunroof Shade - Rattles In Full Open Position > Page 6124 2. With the headlining removed the deadner pad will be visible (Figure 1). Inspect the large deadner pad and the two C-pillar pads. If the deadner pad is completely disengaged, from the roof it must be replaced, proceed to Step 3. If the deadner pad is loose or partially detached it can be reattached following the procedure beginning with Step 4 (Figure 1). 3. Position the new deadner pad as shown in (Figure 1). 4. Use a six inch roller to pressurize and apply the deadner pad. A constant uniform force should be used to apply the pressure across the complete surface of the deadner pad. 5. Use the six inch roller to firmly seat the C-pillar pads. 6. Inspect the rear track bumpers, if they are loose or missing they must be replaced. 7. Remove the loose bumper or locate the bumper that has fallen off and discard. 8. Clean the surface with isopropyl alcohol and let dry. 9. Remove the backing paper from the new bumper and apply to the same location that the old bumper was removed from (Figure 1). Repeat the procedure for the other side. 10. Install the headlining following the procedure in the 1998 Neon Service Manual (Publication No. 81-270-8025) on page 23-20. Insure that the door weatherstrips are properly seated around the headlining. 11. Verity proper operation of the sunroof and confirm that rattle has been eliminated. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Technical Service Bulletins > All Other Service Bulletins for Weatherstrip: > 23-46-98 > Oct > 98 > Sunroof Shade - Rattles In Full Open Position Technical Service Bulletin # 23-46-98 Date: 981009 Sunroof Shade - Rattles In Full Open Position NO: 23-46-98 GROUP: Body DATE: Oct. 9, 1998 SUBJECT: Sunroof Sun Shade Rattles In Full Open Position MODELS: 1997-1998 (PL) Neon SYMPTOM/CONDITION The sunroof sun shade rattles in the full open position due to the roof deadner pad not fully bonding to the roof and/or the track foam/sponge bumpers are coming loose from the track. DIAGNOSIS: Open the sun shade to the full open position. Drive the vehicle and listen for a rattle coming from the sun shade/roof area. If the rattle is heard perform the Repair Procedure. PARTS REQUIRED: AR (1) 4546820 Deadner Pad, Roof Panel AR (1) 05027248AA Bumper, Sunroof Rear Track Pad - Right AR (1) 05027249AA Bumper, Sunroof Rear Track Pad - Left NOTE: THE SUNROOF REAR TRACK BUMPERS MUST BE REPLACED AS A SET. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-10-30-93 1.0 Hrs. Sunshade, Sunroof - Repair - 2 Door Vehicles 23-10-30-94 1.1 Hrs. Sunshade, Sunroof - Repair - 4 Door Vehicles FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves reapplying or replacing the existing deadner pad and/or replacing the rear track pad bumpers as needed. 1. Remove the headlining following the procedure in the 1998 Neon Service Manual (Publication No. 81-270-8025) beginning on page 23-19. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Technical Service Bulletins > All Other Service Bulletins for Weatherstrip: > 23-46-98 > Oct > 98 > Sunroof Shade - Rattles In Full Open Position > Page 6130 2. With the headlining removed the deadner pad will be visible (Figure 1). Inspect the large deadner pad and the two C-pillar pads. If the deadner pad is completely disengaged, from the roof it must be replaced, proceed to Step 3. If the deadner pad is loose or partially detached it can be reattached following the procedure beginning with Step 4 (Figure 1). 3. Position the new deadner pad as shown in (Figure 1). 4. Use a six inch roller to pressurize and apply the deadner pad. A constant uniform force should be used to apply the pressure across the complete surface of the deadner pad. 5. Use the six inch roller to firmly seat the C-pillar pads. 6. Inspect the rear track bumpers, if they are loose or missing they must be replaced. 7. Remove the loose bumper or locate the bumper that has fallen off and discard. 8. Clean the surface with isopropyl alcohol and let dry. 9. Remove the backing paper from the new bumper and apply to the same location that the old bumper was removed from (Figure 1). Repeat the procedure for the other side. 10. Install the headlining following the procedure in the 1998 Neon Service Manual (Publication No. 81-270-8025) on page 23-20. Insure that the door weatherstrips are properly seated around the headlining. 11. Verity proper operation of the sunroof and confirm that rattle has been eliminated. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Motor: > 23-49-99 > Nov > 99 > Sunroof - Ratcheting Noise When Opening Or Closing Sunroof / Moonroof Motor: Customer Interest Sunroof - Ratcheting Noise When Opening Or Closing NUMBER: 23-49-99 GROUP: Body DATE: Nov. 12, 1999 SUBJECT: Sunroof Makes A Ratcheting Type Noise When Opening Or Closing OVERVIEW: This bulletin involves replacing the motor bracket drive tube locator. MODELS: 1996 - 1999 (PL) Neon SYMPTOM/CONDITION: The sunroof makes a ratcheting type noise while opening or closing. The noise is most noticeable at the full open or full closed position. The noise is caused by an oversized drive tube locator allowing the motor gear to override the drive tubes. DIAGNOSIS: While opening and closing the sunroof listen for the ratcheting noise, if the noise is heard perform the Repair Procedure. PARTS REQUIRED: 1 05016539AA Locator, Motor Bracket Drive Tube 4 04856501 Tie Strap REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the sunroof module following the procedure in the 1999 Neon Service Manual (Publication No. 81-270-9125) page 23-14. 2. Ensure that the sunroof module is in the full closed position and remove the sunroof motor from the sunroof module assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Motor: > 23-49-99 > Nov > 99 > Sunroof - Ratcheting Noise When Opening Or Closing > Page 6139 3. With a 3 mm (.012 in.) drill bit remove the rivet holding the locator to the motor bracket (Figure 1). 4. Place the new locator over the drive tubes and secure with the rivet provided with the new locator. Make sure that the spring insert is in place under the bracket (Figure 2). 5. Install the motor. Ensure that the motor is positioned in the same place it was removed from. NOTE: WHEN INSTALLING THE SUNROOF MODULE INSURE THAT THE DRAIN TUBE CLAMPS ARE INSTALLED IN THE POSITION THEY WERE REMOVED FROM DURING DISASSEMBLY. USE A TIE STRAP OR EQUIVALENT TO SECURE THE DRIVE TUBES IN THE SAME LOCATIONS THE CLAMPS WERE REMOVED FROM DURING DISASSEMBLY. 6. Install the sunroof module following the procedure in the 1999 Neon Service Manual (Publication No. 81-270-9125) page 23-14. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-30-64-92 1.7 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Motor: > 23-49-99 > Nov > 99 > Sunroof - Ratcheting Noise When Opening Or Closing Sunroof / Moonroof Motor: All Technical Service Bulletins Sunroof - Ratcheting Noise When Opening Or Closing NUMBER: 23-49-99 GROUP: Body DATE: Nov. 12, 1999 SUBJECT: Sunroof Makes A Ratcheting Type Noise When Opening Or Closing OVERVIEW: This bulletin involves replacing the motor bracket drive tube locator. MODELS: 1996 - 1999 (PL) Neon SYMPTOM/CONDITION: The sunroof makes a ratcheting type noise while opening or closing. The noise is most noticeable at the full open or full closed position. The noise is caused by an oversized drive tube locator allowing the motor gear to override the drive tubes. DIAGNOSIS: While opening and closing the sunroof listen for the ratcheting noise, if the noise is heard perform the Repair Procedure. PARTS REQUIRED: 1 05016539AA Locator, Motor Bracket Drive Tube 4 04856501 Tie Strap REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the sunroof module following the procedure in the 1999 Neon Service Manual (Publication No. 81-270-9125) page 23-14. 2. Ensure that the sunroof module is in the full closed position and remove the sunroof motor from the sunroof module assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Motor: > 23-49-99 > Nov > 99 > Sunroof - Ratcheting Noise When Opening Or Closing > Page 6145 3. With a 3 mm (.012 in.) drill bit remove the rivet holding the locator to the motor bracket (Figure 1). 4. Place the new locator over the drive tubes and secure with the rivet provided with the new locator. Make sure that the spring insert is in place under the bracket (Figure 2). 5. Install the motor. Ensure that the motor is positioned in the same place it was removed from. NOTE: WHEN INSTALLING THE SUNROOF MODULE INSURE THAT THE DRAIN TUBE CLAMPS ARE INSTALLED IN THE POSITION THEY WERE REMOVED FROM DURING DISASSEMBLY. USE A TIE STRAP OR EQUIVALENT TO SECURE THE DRIVE TUBES IN THE SAME LOCATIONS THE CLAMPS WERE REMOVED FROM DURING DISASSEMBLY. 6. Install the sunroof module following the procedure in the 1999 Neon Service Manual (Publication No. 81-270-9125) page 23-14. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-30-64-92 1.7 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6151 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6152 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6153 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6154 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6155 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation Power Door Lock Switch: Description and Operation CIRCUIT OPERATION Left Door Switch Operation (Lock) When the door lock switch is moved to the LOCK position, voltage is supplied on the P35 circuit to the bus bar located inside the right door switch, lock side. Battery voltage is passed through the switch to the P33 circuit to the door motors. Grounding is provided through the P34 circuit for all door motors back to the right door switch. The ground is passed through the bus bar internal to the switch, UNLOCK side, to the P36 circuit. The P36 circuit connects to the left front switch to a bus bar, internal to the switch, and then to the Z8 circuit. The Z8 circuit connects to its grounding point. Left Door Switch Operation (Unlock) When the switch is moved to the UNLOCK position, voltage is supplied on the P36 circuit to the right door switch, unlock side. The battery voltage is passed through the switch internal bus bar to the P34 circuit. The P34 circuit then connects to the door motors on the unlock side. Grounding for the UNLOCK function is provided by the P33 circuit. The P33 circuit connects back to the right door switch, LOCK side, and passes through the internal bus bar to the P35 circuit. The P35 circuit connects back to the left door switch, and passes through the switch to the Z8 circuit. The Z8 circuit goes to it's grounding point. Right Door Switch Operation (Lock) When the switch is moved to the LOCK position, voltage is supplied to the P33 circuit, and then to the door lock motors. The ground path is provided on the P34 circuit back to the right door switch. The ground is passed through the switch internal bus bar to the P36 circuit. The P36 circuit connects to the left door switch and through to the Z8 circuit. The Z8 circuit then connects to the grounding point at the left center instrument panel support. Right Door Switch Operation (Unlock) When the switch is moved to the UNLOCK position voltage is supplied to the P34 circuit from the switch to the door UNLOCK side of the motors. The grounding path is through the LOCK side of the motors, circuit P33, back to the switch. The ground continues through the internal bus bar of the switch on circuit P35 to the left door switch. At the left door switch, the ground passes through that switches internal bus bar to the Z8 grounding point. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Page 6160 Power Door Lock Switch: Testing and Inspection Door Lock Switch Continuity Test Remove the switch from its mounting location. Using an ohmmeter, refer to the Door Lock Switch Continuity Test to determine if continuity is correct in the Lock and Unlock switch positions. If these results are not obtained, replace the switch. Wiring The following wiring test sequence determines whether or not voltage is continuous through the body harness to switch. 1. Remove left side switch from door trim panel. 2. Carefully separate multiple terminal block on wiring harness from switch body. 3. Connect one lead of test light to a ground terminal. Touch other test light lead to Red Wire terminal. a. If test light comes on, the wiring circuit between the battery and switch is functional. b. If test light does not come on, check fuse 3 in the fuse block or for a open circuit. 4. If test light comes on, the wiring circuit between the battery and switch is functional. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Page 6161 Power Door Lock Switch: Service and Repair REMOVAL 1. Remove front door trim. 2. Disconnect wire connector. 3. Remove attaching screws. 4. Remove the switch. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation Power Mirror Switch: Description and Operation CIRCUIT OPERATION The power mirror switch has a right and left position. Moving the switch to either of these positions changes the voltage path internal to the switch (i.e.. changes polarity at the motors). When the switch is moved to the left position and mirror movement UP is selected, voltage is supplied through the P93 circuit and the ground path is through circuit P90. When the DOWN movement is selected the power and ground are reversed. If a left door mirror movement LEFT is selected voltage is supplied through the P95 circuit and the ground is passed through circuit P91. When the left door minor RIGHT movement is selected the power and ground are reversed. When the switch is moved to the right position and mirror movement UP is selected, voltage is supplied through the P92 circuit and the ground path is through circuit P90. When the DOWN movement is selected the power and ground are reversed. If a right door mirror movement LEFT is selected voltage is supplied through the P94 circuit and the ground is passed through circuit P91. When the left door mirror RIGHT movement is selected the power and ground are reversed. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 6165 Power Mirror Switch: Testing and Inspection Mirror Switch Test Mirror Switch Test 1. Remove power mirror switch from mounting position. 2. Disconnect wiring harness at switch connector. 3. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror Switch Test and RHD Power Fold Away Mirror Switch Test. 4. If test results are not obtained as shown, replace the switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 6166 Power Mirror Switch: Service and Repair REMOVAL 1. Remove door trim panel. 2. Remove switch mounting screws from back side of trim panel and remove switch. 3. Disconnect wire connector. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information > Technical Service Bulletins > Competition Package Front Fascia - Information Air Dam: Technical Service Bulletins Competition Package Front Fascia - Information NO: 23-22-98 GROUP: Body DATE: Jun. 12, 1998 SUBJECT: Competition Package (Sales Code ACR) Front Fascia Information MODELS: 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH THE COMPETITION PACKAGE (SALES CODE ACR) ONLY. DISCUSSION: Neon's built with the corn petition package (sales code ACR) are built with the same front fascia as a Sport, Expresso and RT models. The sport model front fascia includes holes for fog lamps. However on the competition package the fog lamps are not installed to allow for additional air flow during racing. If a replacement is necessary to a front fascia on a vehicle equipped with the competition package, it is important that the correct fascia with the fog lamp openings be installed. If a customer requests that fog lamps be added at their expense, they should be advised that if the vehicle is modified from original equipment it may then be illegal for some competition situations. The addition of fog lamps is not a warrantable issue. POLICY: Information Only Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 23-48-97A > Sep > 97 > Roof Rail Weatherstrip - Water Leaks into Vehicle Weatherstrip: Customer Interest Roof Rail Weatherstrip - Water Leaks into Vehicle NO: 23-48-97 Rev. A GROUP: Body DATE: Sep. 19, 1997 SUBJECT: Water Drips From Roof Rail Weatherstrip Channel Into Vehicle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-48-97, DATED AUG. 29, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE PART NUMBERS HAVE BEEN REVISED AND ARE MARKED WITH **ASTERISKS**. MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Water drips from roof rail weatherstrip and retainer channel into vehicle with the door/window open. DISCUSSION: A new anti-drip roof rail retainer channel is available for Sedan and Coupe models. The left and right side roof rail retainer channels must be replaced as a set on 1997 and earlier models due to appearance differences from the existing roof rail retainer channels. PARTS REQUIRED: 1 04724516AA Retainer Channel Assy., Right Front Pillar to Roof Glass Weather Strip, Coupe 1 04724517AA Retainer Channel Assy., Left Front Pillar to Roof Glass Weather Strip, Coupe **1 04724514AA Retainer Channel Assy., Right A to C Pillar Door Glass, Sedan** **1 04724515AA Retainer Channel Assy., Left A to C Pillar Door Glass, Sedan ** 1 04546838 Applique, "B" Pillar, Right 1 04546839 Applique, "B" Pillar, Left REPAIR PROCEDURE: This bulletin involves the replacement of both roof rail retainer channels and B pillar appliques. 1. Open door(s). 2. Using trim stick disengage the top and bottom push in fasteners from "B" pillar applique. Gently pull outward on the applique to remove from the vehicle. NOTE: THE APPLIQUE IS ATTACHED TO THE VEHICLE WITH TWO SIDED TAPE BETWEEN THE PUSH IN FASTENERS, INSURE ALL OF THE OLD TWO SIDED TAPE IS REMOVED FROM THE VEHICLE SURFACE BEFORE INSTALLATION OF NEW PART. 3. Remove the weatherstrip from the retainer channel. 4. Remove the retainer channel from the body side aperture. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 23-48-97A > Sep > 97 > Roof Rail Weatherstrip - Water Leaks into Vehicle > Page 6180 5. Install the new retainer channel, by inserting the push pin(s). Install the remaining screws and torque to 4.9 Nm (44 in. lbs), Figure 1 - Two Door, Figure 2 - Four Door. 6. Install the weatherstrip into the retainer channel. 7. Remove the backing paper from the "B" pillar two sided tape. Place the "B" pillar applique up to the vehicle and push in the two fasteners. Beginning at the top of the "B" pillar, use firm pressure to completely seat the applique. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-02-15-92 2 Door 0.9 Hrs. 23-02-15-93 4 Door 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 23-48-97A > Sep > 97 > Roof Rail Weatherstrip - Water Leaks into Vehicle Weatherstrip: All Technical Service Bulletins Roof Rail Weatherstrip - Water Leaks into Vehicle NO: 23-48-97 Rev. A GROUP: Body DATE: Sep. 19, 1997 SUBJECT: Water Drips From Roof Rail Weatherstrip Channel Into Vehicle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-48-97, DATED AUG. 29, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE PART NUMBERS HAVE BEEN REVISED AND ARE MARKED WITH **ASTERISKS**. MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Water drips from roof rail weatherstrip and retainer channel into vehicle with the door/window open. DISCUSSION: A new anti-drip roof rail retainer channel is available for Sedan and Coupe models. The left and right side roof rail retainer channels must be replaced as a set on 1997 and earlier models due to appearance differences from the existing roof rail retainer channels. PARTS REQUIRED: 1 04724516AA Retainer Channel Assy., Right Front Pillar to Roof Glass Weather Strip, Coupe 1 04724517AA Retainer Channel Assy., Left Front Pillar to Roof Glass Weather Strip, Coupe **1 04724514AA Retainer Channel Assy., Right A to C Pillar Door Glass, Sedan** **1 04724515AA Retainer Channel Assy., Left A to C Pillar Door Glass, Sedan ** 1 04546838 Applique, "B" Pillar, Right 1 04546839 Applique, "B" Pillar, Left REPAIR PROCEDURE: This bulletin involves the replacement of both roof rail retainer channels and B pillar appliques. 1. Open door(s). 2. Using trim stick disengage the top and bottom push in fasteners from "B" pillar applique. Gently pull outward on the applique to remove from the vehicle. NOTE: THE APPLIQUE IS ATTACHED TO THE VEHICLE WITH TWO SIDED TAPE BETWEEN THE PUSH IN FASTENERS, INSURE ALL OF THE OLD TWO SIDED TAPE IS REMOVED FROM THE VEHICLE SURFACE BEFORE INSTALLATION OF NEW PART. 3. Remove the weatherstrip from the retainer channel. 4. Remove the retainer channel from the body side aperture. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 23-48-97A > Sep > 97 > Roof Rail Weatherstrip - Water Leaks into Vehicle > Page 6186 5. Install the new retainer channel, by inserting the push pin(s). Install the remaining screws and torque to 4.9 Nm (44 in. lbs), Figure 1 - Two Door, Figure 2 - Four Door. 6. Install the weatherstrip into the retainer channel. 7. Remove the backing paper from the "B" pillar two sided tape. Place the "B" pillar applique up to the vehicle and push in the two fasteners. Beginning at the top of the "B" pillar, use firm pressure to completely seat the applique. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-02-15-92 2 Door 0.9 Hrs. 23-02-15-93 4 Door 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams Speed Control Servo Connector Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams > Page 6191 Cruise Control Servo: Description and Operation SYSTEM OPERATION The servo unit consists of a solenoid valve body, and a vacuum chamber. The PCM controls the solenoid valve body. The solenoid valve body controls the application and release of vacuum to the diaphragm of the vacuum servo. The servo unit cannot be repaired and is serviced only as a complete assembly. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams > Page 6192 Cruise Control Servo: Testing and Inspection 1. Turn ignition switch to the ON position without starting engine. Activate speed control ON switch. Fig. 4 Servo Harness Connector 2. Disconnect the four-way electrical connector and the vacuum harness at the servo. 3. Connect a jumper wire from Pin 3 of the servo to Pin 3 of the wire connector. 4. Ground Pins 2 and 4 in the servo. Do not connect pin 1. 5. Connect a hand held vacuum pump to the vacuum nipple and apply 10 - 15 inches of vacuum. 6. If servo pulls cables, replace servo. 7. Ground Pin 1 on servo. 8. Check that the throttle cable pulls in and holds as long as the vacuum pump is connected. After one minute, check if cable is still holding. If cable does not hold replace the servo. 9. Disconnect jumper from pin 3. Cable should return to rest position. If not, replace servo. 10. Connect 4 way electrical connector and vacuum harness to servo. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams > Page 6193 Cruise Control Servo: Service and Repair REMOVAL 1. Disconnect electrical connector from servo. 2. Disconnect vacuum hoses from servo. 3. Remove 2 nuts retaining cable to servo. 4. Remove hair pin holding cable to servo. INSTALLATION 1. Install hairpin to cable at servo. 2. Install 2 nuts at cable to servo and servo bracket, tighten to 7 N.m (60 in.lbs.). 3. Connect electrical connector to servo. 4. Connect vacuum hose to servo Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation Cruise Control Servo Cable: Description and Operation SYSTEM OPERATION The speed control servo cable is connected between the speed control vacuum servo diaphragm and the throttle body control linkage. This cable causes the throttle control linkage to open or close the throttle valve in response to movement of the vacuum servo diaphragm. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation > Page 6197 Cruise Control Servo Cable: Service and Repair Throttle Control Shield Throttle Cable Attachment To Throttle Body-Manual Transmission Throttle Cable Attachment To Throttle Body-Automatic Transmission Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation > Page 6198 Disconnecting Throttle Cable - Typical REMOVAL 1. Remove throttle control shield. 2. Remove throttle clasp from the throttle body lever. 3. Remove speed control cable from throttle lever by sliding clasp out hole used for throttle cable. 4. Compress the retaining tabs on the cable and slide cable out of bracket. 5. Disconnect electrical connector from servo. 6. Disconnect vacuum hose from servo 7. Remove 2 nuts retaining bracket to servo. 8. Remove push nuts holding cable housing to servo. 9. Remove retaining clip holding cable to servo. INSTALLATION 1. Install retaining clip to cable at servo. 2. Slide cable bell housing over servo mounting studs. 3. Install servo mounting studs into bracket. 4. Install 2 nuts at cable to servo and servo bracket, tighten to 7 N.m (60 in. lbs.). 5. Connect electrical connector to servo. 6. Connect vacuum hose to servo 7. Slide cable into throttle cable bracket and engage retaining tabs. 8. Rotate the throttle lever forward to the wide open position and install speed control cable clasp. 9. Rotate the throttle lever forward to the wide open position and install throttle cable clasp. 10. Install throttle control shield. Tighten bolt to 5.6N.m (50 in. lbs.). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Description and Operation Cruise Control Switch: Description and Operation SYSTEM OPERATION There are two separate switch pods that operate the speed control system. The steering-wheel/mounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF RESUME/ACCELERATE, SET/COAST and CANCEL modes. Refer to the owner's manual for more information on speed control switch functions and setting procedures. When speed control is selected by depressing the ON switch, the PCM allows a set speed to be stored in RAM for speed control. To store a set speed, depress the COAST/SET switch while the vehicle is moving at a speed between 30 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: An indication of Park or Neutral - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - An rpm increase without a VSS signal increase (indicates that the clutch has been disengaged) - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the RES/ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM is programmed for an acceleration feature. With the RES/ ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the RAM when the RES/ACCEL switch is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the RES/ACCEL switch. The PCM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the SET/COAST switch until the desired speed is reached. Then release the switch. The ON and OFF switches operates two components: the PCM's ON/OFF input, and the battery voltage to the brake switch, which powers the speed control servo. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Page 6202 Cruise Control Switch: Testing and Inspection The speed control switches mounted on the steering wheel contain five switches and four resistors. The PCM sends 5 Volts through pin 41 to the speed control switches. The input on pin 41 is responsible for identifying the following: Resume/Accelerate, Set/ Coast, On, Off and Cancel. This is accomplished by multiplexing. Multiplexing allows the PCM to identify more than one signal from a single wire. To accomplish this, the speed control switch uses resistors that cause different voltage signals at pin 41. The 5-Volt signal at pin 41 has no path to ground when no buttons are depressed, allowing the PCM to recognize the open circuit. When the ON, OFF switch contacts are closed, the 5 Volt signal is pulled through a 15400 ohm resistor to ground providing a voltage of 4.14 to 4.73 Volts at pin 41. Once the PCM recognizes the ON signal, the PCM provides a battery voltage signal to the speed control servo through pin 5 of the 80-way connector. When the SET/COAST switch is depressed, a momentary contact closes a path to ground through a 2,940 ohm resistor. This causes a voltage of approximately 1.99 to 3.20 Volts at pin 41, indicating that the SET/COAST switch has been depressed. When the RES/ACCEL switch is depressed, a momentary contact closes to ground through a 6,650 ohm resistor. The 5-volt signal then passes through a higher resistance than that of the SET/COAST switch, causing the voltage to be approximately 3.30 to 4.14 Volts. When the OFF switch is depressed, the contacts close directly to ground, causing the 5-Volt signal to drop to 0 Volts. When the CANCEL is pressed the contact closes to ground through a 920 ohm resister, causing voltage at pin 41 of 0.61 to 1.94 Volts. Ohmmeter Check Of Switch Speed Control Switch 1. Remove the ON, OFF speed control switch assembly and disconnect the two-way connector. 2. Using an ohmmeter, touch one lead to one Pin and the second lead to the other Pin. The meter should read no continuity. Press the OFF button, the ohmmeter should read 0 to 0.5 ohms. Press the ON button, the ohmmeter should read 15,245 to 15,555 ohms. If the resistance does not fall within these values replace switch. 3. Remove the RESUME/SET/CANCEL speed control switch assembly and disconnect the two-way connector. 4. Using an ohmmeter, touch one lead to one Pin and the second lead to the other Pin. The meter should read no continuity Press the SET button, the ohmmeter should read 2,910 to 2,970 ohms. Press the RESUME button, the ohmmeter should read 6,580 to 6,720 ohms. Press the CANCEL button, the ohmmeter should read 900 to 920 ohms. If the resistance values do not fall within these specification replace the switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Description and Operation Cruise Control Vacuum Reservoir: Description and Operation SYSTEM OPERATION The reservoir contains a one-way check valve to trap engine vacuum in the reservoir. When engine vacuum drops, as in climbing a grade while driving, the reservoir supplies the vacuum needed to maintain proper speed control operation. The vacuum reservoir cannot be repaired and must be replaced if faulty. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Description and Operation > Page 6206 Cruise Control Vacuum Reservoir: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove bolt on top of vacuum reservoir. 3. Remove vacuum hoses. 4. Remove vacuum reservoir. INSTALLATION 1. Install vacuum reservoir, install push pin and tighten screw to 5 N.m (44 in. lbs.). 2. Install vacuum hoses. 3. Lower vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation Cruise Control Switch: Description and Operation SYSTEM OPERATION There are two separate switch pods that operate the speed control system. The steering-wheel/mounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF RESUME/ACCELERATE, SET/COAST and CANCEL modes. Refer to the owner's manual for more information on speed control switch functions and setting procedures. When speed control is selected by depressing the ON switch, the PCM allows a set speed to be stored in RAM for speed control. To store a set speed, depress the COAST/SET switch while the vehicle is moving at a speed between 30 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: An indication of Park or Neutral - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - An rpm increase without a VSS signal increase (indicates that the clutch has been disengaged) - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the RES/ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM is programmed for an acceleration feature. With the RES/ ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the RAM when the RES/ACCEL switch is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the RES/ACCEL switch. The PCM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the SET/COAST switch until the desired speed is reached. Then release the switch. The ON and OFF switches operates two components: the PCM's ON/OFF input, and the battery voltage to the brake switch, which powers the speed control servo. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Page 6211 Cruise Control Switch: Testing and Inspection The speed control switches mounted on the steering wheel contain five switches and four resistors. The PCM sends 5 Volts through pin 41 to the speed control switches. The input on pin 41 is responsible for identifying the following: Resume/Accelerate, Set/ Coast, On, Off and Cancel. This is accomplished by multiplexing. Multiplexing allows the PCM to identify more than one signal from a single wire. To accomplish this, the speed control switch uses resistors that cause different voltage signals at pin 41. The 5-Volt signal at pin 41 has no path to ground when no buttons are depressed, allowing the PCM to recognize the open circuit. When the ON, OFF switch contacts are closed, the 5 Volt signal is pulled through a 15400 ohm resistor to ground providing a voltage of 4.14 to 4.73 Volts at pin 41. Once the PCM recognizes the ON signal, the PCM provides a battery voltage signal to the speed control servo through pin 5 of the 80-way connector. When the SET/COAST switch is depressed, a momentary contact closes a path to ground through a 2,940 ohm resistor. This causes a voltage of approximately 1.99 to 3.20 Volts at pin 41, indicating that the SET/COAST switch has been depressed. When the RES/ACCEL switch is depressed, a momentary contact closes to ground through a 6,650 ohm resistor. The 5-volt signal then passes through a higher resistance than that of the SET/COAST switch, causing the voltage to be approximately 3.30 to 4.14 Volts. When the OFF switch is depressed, the contacts close directly to ground, causing the 5-Volt signal to drop to 0 Volts. When the CANCEL is pressed the contact closes to ground through a 920 ohm resister, causing voltage at pin 41 of 0.61 to 1.94 Volts. Ohmmeter Check Of Switch Speed Control Switch 1. Remove the ON, OFF speed control switch assembly and disconnect the two-way connector. 2. Using an ohmmeter, touch one lead to one Pin and the second lead to the other Pin. The meter should read no continuity. Press the OFF button, the ohmmeter should read 0 to 0.5 ohms. Press the ON button, the ohmmeter should read 15,245 to 15,555 ohms. If the resistance does not fall within these values replace switch. 3. Remove the RESUME/SET/CANCEL speed control switch assembly and disconnect the two-way connector. 4. Using an ohmmeter, touch one lead to one Pin and the second lead to the other Pin. The meter should read no continuity Press the SET button, the ohmmeter should read 2,910 to 2,970 ohms. Press the RESUME button, the ohmmeter should read 6,580 to 6,720 ohms. Press the CANCEL button, the ohmmeter should read 900 to 920 ohms. If the resistance values do not fall within these specification replace the switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation ANTILOCK BRAKE SYSTEM (ABS) AMBER WARNING LAMP The ABS system uses an Amber ABS Warning Lamp, located in the instrument cluster. The purpose of the warning lamp is discussed in detail below. When Detection Occurs The ABS warning lamp will turn on when the Controller Antilock Brake (CAB) detects a condition which results in a shutdown of ABS function. The ABS Warning Lamp is normally on until the CAB completes its self tests and turns the lamp off (approximately 4-5 seconds after the ignition switch is turned on). When the ABS warning lamp is on, only the ABS function of the brake system if affected. The standard brake system and the ability to stop the car will not be affected when only the ABS warning lamp is on. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Headlamp on Chime Audible Warning Device: Description and Operation Headlamp on Chime CIRCUIT OPERATION The headlamp ON chime is used to indicate to the operator that the headlamps or parking lamps are ON when the drivers door is OPEN. If the lamps are ON and the drivers door is opened, a ground path is completed from the G26 circuit at the cluster, through the headlamp switch, to the G16 circuit and ending at the door ajar switch. The door ajar switch is case grounded. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Headlamp on Chime > Page 6220 Audible Warning Device: Description and Operation Key-In Chime CIRCUIT OPERATION The key-in chime is used to indicate to the operator that the key is in the ignition with the drivers door OPEN. If the key is in the ignition and the drivers door is OPEN, a ground path is completed from the G26 circuit at the cluster, through the CLOSED key-in switch, to the G16 circuit and terminating at the door ajar switch which is case grounded. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions NUMBER: 26-12-97F GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997-1998 Teves Mark IV, Teves Mark 20 ABS Diagnostic Manual - Publication Number 81-699-97012 DESCRIPTION OF CHANGES Revisions to the ABS warning light procedure Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions > Page 6225 244 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions > Page 6226 245 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > General Information Brake Warning Indicator: Description and Operation General Information Master Cylinder Fluid Level Sensor GENERAL INFORMATION The red Brake warning lamp is located in the instrument panel cluster and is used to indicate a low brake fluid condition or that the parking brake is applied. In addition, the brake warning lamp is turned on as a bulb check by the ignition switch when the ignition switch is placed in the crank position. Problems with this system will generally be of the type where the warning lamp fails to turn on when it should, or remains on when it should not. The warning lamp bulb is supplied a 12 volt ignition feed anytime the ignition switch is on. The bulb is then illuminated by completing the ground circuit either through the park brake switch, the fluid level sensor in the master cylinder reservoir, or the ignition switch in the crank position. PURPOSE The Brake Fluid Level sensor is located in the brake fluid reservoir of the master cylinder assembly. The purpose of the sensor is to provide the driver with an early warning that the brake fluid level in the master cylinder reservoir has dropped to below normal. This may indicate an abnormal loss of brake fluid in the master cylinder fluid reservoir resulting from a leak in the hydraulic system. As the fluid drops below the minimum level, the fluid level sensor closes the brake warning light circuit. This will turn on the red brake warning light. At this time, master cylinder fluid reservoir should be checked and filled to the full mark with DOT 3 brake fluid. NOTE: If brake fluid level has dropped in master cylinder fluid reservoir, the entire brake hydraulic system should he checked for evidence of a leak. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > General Information > Page 6229 Brake Warning Indicator: Description and Operation ABS Warning Lamp Circuit Operation CIRCUIT OPERATION The ABS warning lamp is an output from the Controller Anti Lock Brake (CAB) and the Antilock Brake System (ABS) relay box. It is used to alert the operator of a problem in the ABS system. The G19 circuit from the CAB and the ABS system relay is used to detect a problem. If a problem is detected, the CAB grounds the G19 circuit and illuminates the lamp in the instrument cluster. Circuit G19 is also an output of the CAB to the ABS system relay contact side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > General Information > Page 6230 Brake Warning Indicator: Description and Operation Brake Warning Lamp Circuit Operation CIRCUIT OPERATION The Brake Warning Indicator lamp is used to alert the operator of a problem with the vehicles braking system. The lamp illuminates when the ignition switch is turned to START position to perform a self check. There are two switches used in this system and they are wired in parallel form. A parking brake switch located on the parking brake mechanism will illuminate the lamp if the normally OPEN switch is CLOSED. This switch is case grounded. The other switch used is the brake warning lamp switch. This switch is normally OPEN. When the brake system pressure is below a predetermined level the switch CLOSES and completes a path to ground from the G9 circuit at the cluster, through the switch, to the left headlamp ground. If the vehicle is built for use in Canada the parking brake switch is used for the Daytime Running Lamp Module (DRL). Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Testing and Inspection > Brake System Warning Lamp Test Brake Warning Indicator: Testing and Inspection Brake System Warning Lamp Test The brake warning lamp illuminates when the parking brake is applied with ignition switch turned to the ON position. The same lamp will also illuminate if one of the two service brake systems fail the when brake pedal is applied. To test the system: - As the ignition switch is turned to the start position the lamp should light. - Turn ignition switch to the ON position and apply the parking brake. The lamp should light. If lamp fails to light inspect for: - A burned out lamp - Loose, corroded or damaged socket - A damaged circuit board - A broken or disconnected wire at the switch - Defective switch Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Testing and Inspection > Brake System Warning Lamp Test > Page 6233 Brake Warning Lamp Functional Check Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Testing and Inspection > Brake System Warning Lamp Test > Page 6234 Brake Warning Indicator: Testing and Inspection Helpful Information - Check the 5 Amp fuse in cavity 11 of the fuse block. - Check the 4 Amp fuse in cavity 12 of the fuse block. - Check the Ignition Off Draw fuse in the PDC. - Check for a good ground at the instrument panel left center support. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Description and Operation Charge Lamp/Indicator: Description and Operation CIRCUIT OPERATION The Charge Indicator lamp is used to alert the operator that the charging system voltage has fallen below the normal operating range. This circuit is controlled by the Powertrain Control Module (PCM). When the PCM determines a problem, it grounds the G12 circuit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6242 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6243 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6244 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6245 Symbol Identification Various symbols are used throughout the Diagrams. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6246 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6247 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6248 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6249 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Fusible Link Replacement On PL vehicles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal. A service part is available if this fusible link requires replacement. This service part has the eyelet that attaches to the starter motor. If the fusible link requires replacement this indicates a problem in the charging/starting system that needs to be corrected. Replacement of the fusible link is the same as repairing a wire. Refer to the wiring repair information for soldering information. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6250 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6251 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6252 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6253 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6254 Cigarette Lighter: Diagnostic Aids Harness Connector Inspection When an intermittent or open circuit is suspected it is important to check for a spread terminal. To accomplish this remove the suspect female terminal from its connector. Check the female terminal for drag when mated with the appropriate male terminal. If the terminal is spread (no or little drag felt) replace the terminal using the procedures covered. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6255 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6256 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6257 Cigarette Lighter: Electrical Diagrams Horns/Cigar Lighter NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6258 Cigarette Lighter: Description and Operation CIRCUIT OPERATION The cigar lighter is powered by a 40 Amp fuse located in the Power Distribution Center (PDC). There is also a 15 Amp fuse located in cavity 1 of the fuse block dedicated for the cigar lighter. When the operator presses the lighter, contacts inside of the lighter element CLOSE and voltage flows through the heating element to ground. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6259 Cigarette Lighter: Testing and Inspection - Check the 40 Amp fuse located in the PDC. - Check the 15 Amp fuse located in the fuse block. - Check for a good ground at the instrument panel left center support. - Check the cigar lighter element. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6260 Cigarette Lighter: Service and Repair REMOVAL 1. Remove the cigar lighter element. 2. Reach underneath the instrument panel through the bottom access hole and disconnect the cigar lighter receptacle wiring connectors. 3. Unscrew the cigar lighter receptacle shell from the receptacle and remove from the base instrument panel. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Description and Operation Clock: Description and Operation SYSTEM OPERATION The electronic digital clock is in the radio. The clock and radio each use the display panel built into the radio. A digital readout indicates the time in hours and minutes whenever the ignition switch is in the ON or ACC position. When the ignition switch is in the OFF position, or when the radio frequency is being displayed, time keeping is accurately maintained. The procedure for setting the clock varies slightly with each radio. The correct procedure is described in the individual radio operating instructions. Refer to the Owner's Manual supplied with the vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components . Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 6269 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming 1. Verify that the negative battery cable is disconnected and isolated. 2. Connect scan tool (DRB) to Data Link connector, located at right side of the steering column and at the lower edge of the lower instrument panel. 3. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 4. After checking that no one is inside the vehicle, connect the battery negative terminal. 5. Using the scan tool, read and record active diagnostic code data. 6. Read and record any stored diagnostic codes. 7. Refer to the airbag system Diagnostic Test if any diagnostic codes are found in Step 5 or Step 6. 8. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the airbag system Diagnostic Test. If the airbag warning lamp either fails to light with the ignition switch ON, or the light goes on and stays on, there is a system malfunction. Refer to the airbag system Diagnostic Test. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Service and Repair Door/Trunk Ajar Indicator/Lamp: Service and Repair REMOVAL The trunk lamp snaps into the rear shelf panel reinforcement under/below the package shelf. 1. Remove the socket assembly by reaching up above the sheet metal. Push the snap inward and downward and remove the assembly 2. Remove the lamp from socket and pull the socket from the lens. Replace as necessary INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: Customer Interest Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 6281 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps Improper Operation Door Switch: All Technical Service Bulletins Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps Improper Operation > Page 6287 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation Fuel Gauge: Description and Operation CIRCUIT OPERATION The fuel level gauge is connected to the fuel pump module on the G4 circuit. The fuel pump module contains the fuel pump and a variable resistor for the gauge. Grounding for the fuel pump module is provided on the Z2 circuit and terminates at the left rear wheel house. The logic driven gauge moves in response to the measured resistance of the fuel tank sending unit. The fuel level sensor contains a variable resistor. As the position of the float and on the level sensor changes, the resistor changes the current flow through the fuel gauge circuit. A change in current flow alters the magnetic field in the fuel gauge which changes the pointer position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation > Page 6291 Fuel Gauge: Testing and Inspection Fuel Gauge 1. Disconnect the fuel gauge sending unit. 2. Turn the ignition switch to the ON position. The fuel gauge should be at its lowest position. Turn the ignition switch OFF. 3. Ground fuel gauge sending unit connector Pin 3. Turn ignition switch to the ON position. The fuel gauge should be at its highest position. Turn ignition switch OFF then ON, after a sending unit signal change to disable the cluster electronic gauge dampening mechanism. a. If OK, check the fuel gauge sending unit connector for proper connection. b. If not OK, connect the sending unit. Remove the cluster and check for an open or short in the sending unit wiring. The sending unit will be less than 1080 Ohms and greater than 50 Ohms depending upon fuel level. If the - sending unit wiring is open or a short circuit, repair as necessary c. If the sending unit wiring is OK, replace the gauge assembly If the condition persists, replace the cluster printed circuit board. Cluster Wire Harness Connector Powertrain Control Module Pin Location Fuel Gauge Incorrectly Indicates Empty The fuel system uses both the instrument cluster and the Powertrain Control Module (PCM) to monitor the fuel level sending unit. If the PCM fuel monitoring circuits senses an open circuit, the increased circuit resistance will causes a false fuel gauge empty reading. Check for continuity between cluster wire harness connector Pin J2-10 and Pin 23 of the PCM. If there is no continuity, repair as necessary If there is continuity, refer to Fuel Gauge test. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > General Description Fuel Gauge Sender: Description and Operation General Description Fig. 10 Level Sensor Diagnosis OPERATION The fuel gauge sending unit is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and two variable resistors (tracks). These two tracks are used to send two different electrical signals. One is used for fuel gauge operation and the other is for OBD II emission requirements. Track 1 fuel gauge operation: As the fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge on the instrument panel to read full. As the fuel level decreases, the float and arm move down. This increases the sending unit resistance, causing the fuel gauge on the instrument panel to read empty Track 2-OBD II emission requirements: A variable voltage signal is sent to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes if the fuel level in the tank is less than 15 percent of its rated capacity. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > General Description > Page 6296 Fuel Gauge Sender: Description and Operation Related Trouble Codes and Set Conditions Fuel Level Sending Unit Volts Too High Name of Code: Fuel Level Sending Unit Volts Too High When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes above a calculated value. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel systems monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Open sensor signal circuit - Fuel level sending unit failure - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Fuel Level Sending Unit Volts Too Low Name of Code: Fuel Level Sending Unit Volts Too Low When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes below 0.10 volts. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel system monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Sensor signal circuit shorted to ground - Fuel level sending unit failure - Loss of fuel ignition switch output voltage - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Sending Unit Operation Check Fuel Gauge Sender: Testing and Inspection Sending Unit Operation Check When a problem occurs with a cluster gauge check for a defective sending unit or wiring. Do this before disassembling the cluster. 1. Sending units and wiring can be checked by grounding the connector leads at the sending unit in the vehicle. 2. With the ignition in the ON position, a grounded input will cause the fuel or temperature gauge to read at or above maximum. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 6299 Fuel Gauge Sender: Testing and Inspection Sending Unit Voltage Check Fig. 1 Fuel Guage Test Terminal 1. Remove the fuel gauge electrical harness. 2. Connect 12 volt test light to the fuel gauge and ground terminal. 3. Turn ignition to On position and proceed as follows: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 6300 a. If test light illuminates and pointer of gauge does not swing, replace fuel gauge. b. If test light illuminates and pointer of gauge swings, replace fuel gauge unit. c. If test light does not light and pointer of gauge does not swing, check the electrical harness for kinks chaffing and broken wires. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 6301 Fuel Gauge Sender: Testing and Inspection Sending Unit Resistance Check Fig. 10 Level Sensor Diagnosis This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. To test the level sensor, connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector. Move the float lever to the positions shown in the resistance chart. Record the resistance at each point. Replace the level sensor if the resistance is not within specifications. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 6302 Fuel Gauge Sender: Service and Repair Fig. 21 Fuel Pump/Level Sensor Electrical Connector NOTE: Remove fuel pump module prior to beginning this procedure. REMOVAL 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector. Fig. 22 Wire Terminal Locking Wedge 2. Pull off blue locking wedge. Fig. 23 Wire Terminal Locking Finger 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 6303 Fig. 24 Removing Wires From Connector 4. Push level sensor signal and ground terminals out of the connector. Fig. 25 Loosening Level Sensor 5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Fig. 26 Level Sensor Removal/Installation 6. Push level sensor down slightly. - Ensure tab at bottom of sensor locks in place. 7. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 8. Install locking wedge on connector. 9. Push connector up into bottom of fuel pump module electrical connector. 10. Install fuel pump module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components . Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 6309 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming 1. Verify that the negative battery cable is disconnected and isolated. 2. Connect scan tool (DRB) to Data Link connector, located at right side of the steering column and at the lower edge of the lower instrument panel. 3. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 4. After checking that no one is inside the vehicle, connect the battery negative terminal. 5. Using the scan tool, read and record active diagnostic code data. 6. Read and record any stored diagnostic codes. 7. Refer to the airbag system Diagnostic Test if any diagnostic codes are found in Step 5 or Step 6. 8. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the airbag system Diagnostic Test. If the airbag warning lamp either fails to light with the ignition switch ON, or the light goes on and stays on, there is a system malfunction. Refer to the airbag system Diagnostic Test. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Service and Repair Instrument Panel Circuit Board: Service and Repair REMOVAL 1. Remove the cluster. Cluster Assembly 2. Remove the attaching screws and rear cover. The bottom screws attaching lens to housing can be accessed without removing foam pad. Printed Circuit Board 3. Disconnect the odometer connector and remove eight attaching screws that attach the printed circuit board and housing. 4. Carefully remove printed circuit board from the cluster. INSTALLATION - For installation reverse the above procedures. Carefully place board on the cluster and ensure that the odometer connector is placed through the board. Gently press board on cluster with a slight rocking motion to ensure pins on gauges line up. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation Low Fuel Lamp/Indicator: Description and Operation CIRCUIT OPERATION The low fuel lamp is used to indicate to the operator that the fuel level is below a predetermined level. This lamp is logic driven by the instrument cluster. When the instrument cluster determines a low fuel condition based on an input from the fuel tank gauge level sending unit (circuit G4) it illuminates the lamp. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > Page 6316 Low Fuel Lamp/Indicator: Testing and Inspection The low fuel warning lamp receives its signal from the fuel gauge drive circuit. Due to production variations, the point where the lamp illuminates, may vary from 1/16 to 3/16 mark on the fuel gauge. There is a built in time delay before the lamp illuminates. This prevents the lamp from going on and off under various road conditions. 1. Verify that the fuel gauge is operating properly 2. Check the low fuel warning lamp assembly. 3. If the lamp still does not function under a low fuel condition replace the printed circuit board. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation CIRCUIT OPERATION The Service Engine Soon lamp illuminates when the ignition switch is in the ON position and prior to starting the vehicle. The lamp will turn off after the vehicle is started. If while the vehicle is running a problem is detected in the engine control system the lamp is illuminated. This is accomplished by the Powertrain Control Module (PCM) grounding the G3 circuit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation Odometer: Description and Operation CIRCUIT OPERATION The speedometer and odometer receive their information on the G7 circuit from the Vehicle Speed Sensor (VSS) on vehicles equipped with the manual or 3-spd automatic transmission. On vehicles equipped with the 41TE transmission the G7 circuit connects from the Transmission Control Module (TCM) to the instrument duster. This circuit also provides a signal to the Powertrain Control Module (PCM). Logic internal to the cluster steps the odometer at a high rate to indicate the proper mileage Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation > Page 6323 Odometer: Service and Repair REMOVAL 1. Remove the instrument panel top cover and cluster bezel. Odometer 2. Remove the four screws attaching cluster to instrument panel. 3. Remove the cluster. 4. Remove the screws attaching PC board cover to cluster. 5. Disconnect the odometer connector from the printed circuit board. 6. Remove the screws attaching lens, dial and gauge assembly to the housing. The bottom screws attaching lens to the housing can be accessed without removing the foam pad. 7. Remove the lens, dial and gauge assembly from housing. 8. Remove the two screws holding the odometer to dial and gauge assembly When setting the dial/gauge and/or cluster assembly down, it must be face up or the gauge operation will be damaged. INSTALLATION - For installation, reverse the above procedures. Carefully place the dial and gauge assembly on the cluster and ensure that the odometer connector is placed through the board. Install with a slight rocking motion to ensure the pins on gauges line up. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation CIRCUIT OPERATION The low oil pressure lamp is used to indicate to the operator that the engine oil pressure has dropped below a predetermined pressure. Power for the lamp is provided on the G5 circuit which also powers the other warning lamps. When the oil pressure is low the normally OPEN oil pressure switch CLOSES completing a path to ground on circuit G6. The oil pressure switch is case grounded to the engine block. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Testing and Inspection > Low Oil Pressure Warning Lamp Test Oil Pressure Warning Lamp/Indicator: Testing and Inspection Low Oil Pressure Warning Lamp Test CAUTION: Disconnect the battery negative cable before servicing the instrument panel or components. When power is required for test purposes, connect battery cable for test only. Disconnect the battery negative cable afier test and before continuing service procedures. The low oil pressure warning lamp will illuminate when the ignition switch is turned to the ON position without engine running. The lamp also illuminates if the engine oil pressure drops below a safe oil pressure level. Oil Pressure Switch To test the system, turn the ignition switch to the ON position. If the lamp fails to light, inspect for a broken or disconnected wire at the oil pressure switch, located at the front of the engine. If the wire at the connector checks good, pull the connector loose from the switch and with a jumper wire, ground the connector to the engine. With the ignition switch turned to the ON position, check the warning lamp. If the lamp still fails to light, inspect for a burned out lamp or disconnected socket in the cluster. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Testing and Inspection > Low Oil Pressure Warning Lamp Test > Page 6329 Oil Pressure Warning Lamp/Indicator: Testing and Inspection Low Oil Warning Circuit The low fuel warning lamp receives its-signal from the fuel gauge drive circuit. Due to production variations, the point where the lamp illuminates, may vary from 1/16 to 3/16 mark on the fuel gauge. There is a built in time delay before the lamp illuminates. This prevents the lamp from going on and off under various road conditions. 1. Verify that the fuel gauge is operating properly 2. Check the low fuel warning lamp assembly. 3. If the lamp still does not function under a low fuel condition replace the printed circuit board. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation CIRCUIT OPERATION The fasten seat belt indicator is used with the warning chime to indicate to the operator to fasten the seat belt. There is a switch located in the drivers side B-pillar that is normally OPEN with the seat belt buckled. If the seat belt is not buckled the switch CLOSES and a ground path is completed from the G10 circuit to the Z1 circuit. This will illuminate the lamp in the instrument cluster. When the ignition switch is moved to the START position the lamp will illuminate. Logic internal to the instrument cluster determines the length of time. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: Customer Interest Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 6342 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: All Technical Service Bulletins Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 6348 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > General Description Fuel Gauge Sender: Description and Operation General Description Fig. 10 Level Sensor Diagnosis OPERATION The fuel gauge sending unit is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and two variable resistors (tracks). These two tracks are used to send two different electrical signals. One is used for fuel gauge operation and the other is for OBD II emission requirements. Track 1 fuel gauge operation: As the fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge on the instrument panel to read full. As the fuel level decreases, the float and arm move down. This increases the sending unit resistance, causing the fuel gauge on the instrument panel to read empty Track 2-OBD II emission requirements: A variable voltage signal is sent to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes if the fuel level in the tank is less than 15 percent of its rated capacity. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > General Description > Page 6353 Fuel Gauge Sender: Description and Operation Related Trouble Codes and Set Conditions Fuel Level Sending Unit Volts Too High Name of Code: Fuel Level Sending Unit Volts Too High When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes above a calculated value. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel systems monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Open sensor signal circuit - Fuel level sending unit failure - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Fuel Level Sending Unit Volts Too Low Name of Code: Fuel Level Sending Unit Volts Too Low When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes below 0.10 volts. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel system monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Sensor signal circuit shorted to ground - Fuel level sending unit failure - Loss of fuel ignition switch output voltage - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Sending Unit Operation Check Fuel Gauge Sender: Testing and Inspection Sending Unit Operation Check When a problem occurs with a cluster gauge check for a defective sending unit or wiring. Do this before disassembling the cluster. 1. Sending units and wiring can be checked by grounding the connector leads at the sending unit in the vehicle. 2. With the ignition in the ON position, a grounded input will cause the fuel or temperature gauge to read at or above maximum. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 6356 Fuel Gauge Sender: Testing and Inspection Sending Unit Voltage Check Fig. 1 Fuel Guage Test Terminal 1. Remove the fuel gauge electrical harness. 2. Connect 12 volt test light to the fuel gauge and ground terminal. 3. Turn ignition to On position and proceed as follows: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 6357 a. If test light illuminates and pointer of gauge does not swing, replace fuel gauge. b. If test light illuminates and pointer of gauge swings, replace fuel gauge unit. c. If test light does not light and pointer of gauge does not swing, check the electrical harness for kinks chaffing and broken wires. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Sending Unit Operation Check > Page 6358 Fuel Gauge Sender: Testing and Inspection Sending Unit Resistance Check Fig. 10 Level Sensor Diagnosis This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. To test the level sensor, connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector. Move the float lever to the positions shown in the resistance chart. Record the resistance at each point. Replace the level sensor if the resistance is not within specifications. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 6359 Fuel Gauge Sender: Service and Repair Fig. 21 Fuel Pump/Level Sensor Electrical Connector NOTE: Remove fuel pump module prior to beginning this procedure. REMOVAL 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector. Fig. 22 Wire Terminal Locking Wedge 2. Pull off blue locking wedge. Fig. 23 Wire Terminal Locking Finger 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 6360 Fig. 24 Removing Wires From Connector 4. Push level sensor signal and ground terminals out of the connector. Fig. 25 Loosening Level Sensor 5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Fig. 26 Level Sensor Removal/Installation 6. Push level sensor down slightly. - Ensure tab at bottom of sensor locks in place. 7. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 8. Install locking wedge on connector. 9. Push connector up into bottom of fuel pump module electrical connector. 10. Install fuel pump module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation CIRCUIT OPERATION The PRNDL lamp receives power on the E2 circuit from the 4 Amp fuse located in the fuse block in cavity 12. The fuse receives power from the headlamp switch. Circuit E2 also powers the ash receiver lamp. When the headlamp switch is moved to the PARK or ON position, current flows through the fuse to the PRNDL lamp. The ground for the lamp is supplied on the Z3 circuit, and terminates at the instrument panel left center support. This circuit is also spliced in with the ash receiver lamp, the ignition switch lamp, and the glove box lamp. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation Speedometer Head: Description and Operation CIRCUIT OPERATION The speedometer and odometer receive their information on the G7 circuit from the Vehicle Speed Sensor (VSS) on manual and 3-spd automatic transmission applications. On vehicles equipped with the 41TE transmission circuit G7 connects from the Transmission Control Module (TCM) to the instrument cluster. The G7 circuit also provides a signal to the Powertrain Control Module (PCM). Logic internal to the instrument cluster adjusts the position of the gauge pointer to the correct vehicle speed using the signal on the G7 circuit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation > Page 6367 Speedometer Head: Testing and Inspection The vehicle is equipped with a electronically driven speedometer and odometer assemblies. A signal is sent from a transmission-mounted vehicle speed sensor to the speedometer circuitry through the wiring harness. Diagnosis of the vehicle speed sensor and circuit, the Chrysler Collision Detection (CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For diagnosis of the speedometer, refer to Powertrain Management / Computers and Control Systems / Vehicle Speed Sensor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Technical Service Bulletins > Customer Interest for Tachometer: > 08-04-98 > Jan > 98 > Tachometer - Fluctuates and/or Bounces Technical Service Bulletin # 08-04-98 Date: 980130 Tachometer - Fluctuates and/or Bounces NO: 08-04-98 GROUP: Electrical DATE: Jan. 30, 1998 SUBJECT: Tachometer Fluctuates And/Or Bounces MODELS: 1997-1998 (PL) Neon THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A TACHOMETER, BUILT PRIOR TO DECEMBER 12, 1997 (MDH 1212XX). SYMPTOM/CONDITION: Tachometer fluctuates and/or bounces as much as 300 to 1000 RPM while driving at a steady speed/RPM. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB Ill) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. Using an ohmmeter, check the resistance between the PCM case and the battery ground. If the resistance is less than 1 ohm, refer to the appropriate Powertrain Diagnostic Manual for further tachometer diagnostics. If the resistance is more than 1 ohm, perform the Repair Procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-01-98 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves tightening the four screws holding the case of the Powertrain Control Module (PCM) to ensure complete grounding. If the ground is incomplete, the signal to the tachometer is momentarily interrupted. 1. Disconnect the negative and positive cables from the battery. 2. Remove the washer bottle neck. 3. Squeeze the tabs on the Power Distribution Center (PDC) while pulling up to remove the PDC from the mounting bracket. Lay the PDC aside to gain access to the PCM bracket screws. 4. Remove the three screws attaching the PCM to the body. 5. Lift the PCM up and disconnect the two 40-way connectors. 6. Remove the PCM. 7. Turn the PCM over to the back side. Torque the four screws (at each corner) to 6.8 Nm (60 in. lbs.) using a manual torque wrench. 8. Attach the two 40-way connectors to the PCM. 9. Install the PCM. Torque the mounting screws to 9 Nm (80 in. lbs.). 10. Install the PDC by pushing it down into the brackets. 11. Install the washer bottle neck. 12. Connect the positive and negative battery cables. 13. Using an ohmmeter, check the resistance between the PCM case and the battery ground. If the resistance is less than 1 ohm, the repair is complete. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Technical Service Bulletins > Customer Interest for Tachometer: > 08-04-98 > Jan > 98 > Tachometer - Fluctuates and/or Bounces > Page 6376 14. If the resistance is above 1 ohm, remove the PCM and perform the following steps: A. Remove one PCM corner screw at a time, then insert back into the hole, and torque to 6.8 Nm (60 in. lbs.). This will work the screw through the paint creating a better ground. B. Repeat for remaining three screws. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tachometer: > 08-04-98 > Jan > 98 > Tachometer Fluctuates and/or Bounces Technical Service Bulletin # 08-04-98 Date: 980130 Tachometer - Fluctuates and/or Bounces NO: 08-04-98 GROUP: Electrical DATE: Jan. 30, 1998 SUBJECT: Tachometer Fluctuates And/Or Bounces MODELS: 1997-1998 (PL) Neon THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A TACHOMETER, BUILT PRIOR TO DECEMBER 12, 1997 (MDH 1212XX). SYMPTOM/CONDITION: Tachometer fluctuates and/or bounces as much as 300 to 1000 RPM while driving at a steady speed/RPM. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB Ill) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. Using an ohmmeter, check the resistance between the PCM case and the battery ground. If the resistance is less than 1 ohm, refer to the appropriate Powertrain Diagnostic Manual for further tachometer diagnostics. If the resistance is more than 1 ohm, perform the Repair Procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-01-98 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves tightening the four screws holding the case of the Powertrain Control Module (PCM) to ensure complete grounding. If the ground is incomplete, the signal to the tachometer is momentarily interrupted. 1. Disconnect the negative and positive cables from the battery. 2. Remove the washer bottle neck. 3. Squeeze the tabs on the Power Distribution Center (PDC) while pulling up to remove the PDC from the mounting bracket. Lay the PDC aside to gain access to the PCM bracket screws. 4. Remove the three screws attaching the PCM to the body. 5. Lift the PCM up and disconnect the two 40-way connectors. 6. Remove the PCM. 7. Turn the PCM over to the back side. Torque the four screws (at each corner) to 6.8 Nm (60 in. lbs.) using a manual torque wrench. 8. Attach the two 40-way connectors to the PCM. 9. Install the PCM. Torque the mounting screws to 9 Nm (80 in. lbs.). 10. Install the PDC by pushing it down into the brackets. 11. Install the washer bottle neck. 12. Connect the positive and negative battery cables. 13. Using an ohmmeter, check the resistance between the PCM case and the battery ground. If the resistance is less than 1 ohm, the repair is complete. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tachometer: > 08-04-98 > Jan > 98 > Tachometer Fluctuates and/or Bounces > Page 6382 14. If the resistance is above 1 ohm, remove the PCM and perform the following steps: A. Remove one PCM corner screw at a time, then insert back into the hole, and torque to 6.8 Nm (60 in. lbs.). This will work the screw through the paint creating a better ground. B. Repeat for remaining three screws. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Technical Service Bulletins > Page 6383 Tachometer: Description and Operation CIRCUIT OPERATION The tachometer is connected to the Powertrain Control Module (PCM) on the G21 circuit. It uses solid state circuity to decode the ignition pulses received from the PCM to adjust the gauge pointer to the proper position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Technical Service Bulletins > Page 6384 Tachometer: Testing and Inspection 1. Remove the cluster. Cluster Wire Harness Connector 2. Check for battery voltage at Pin J1-6 of the cluster wire harness connector. 3. With the ignition switch in the ON position, check for battery voltage at Pin J1-5 connector. 4. Check Pin J1-8 of the connector for continuity to ground. 5. Check for tachometer signal from the Powertrain Control Module by connecting an AC DIGITAL VOLTMETER to Pin J1-7 of the connector and ground. A reading of at least 1.0 Volt should be present with the engine running. a. If the voltage is NOT within specification, go to Step 6. b. If the voltage is within specification go to Step 7. Powertrain Control Module Pin Location 6. If there is less than 1.0 Volt at Pin J1-7 of the connector, check for continuity between Pin J1-7 and Pin 73 of the Powertrain Control Module connector. Also, check the connector at the Powertrain Control Module for damaged pins or terminal push outs. 7. If the voltage is less than 1.0 Volt at Pin J1-7 of the connector and there is continuity between Pin J1-7 and Pin 73 of the PCM connector, replace the Powertrain Control Module. 8. If all tests performed test good, replace the dial and gauge assembly 9. If the tachometer continues to be inoperative, replace the print circuit board. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation CIRCUIT OPERATION The temperature gauge is connected to the engine coolant temperature sensor on the G20 circuit. The engine coolant temperature sensor for the gauge is a combination unit. One side of the unit is used for the Powertrain Control Module (PCM) and the other side for the cluster. The sending unit is case grounded to the engine. The logic driven gauge moves in response to the measured resistance of the engine coolant temperature sending unit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation > Page 6388 Temperature Gauge: Testing and Inspection Engine Coolant Temperature Sensor 1. Disconnect the coolant temperature sensor. 2. Turn ignition switch ON. The temperature gauge should be at its lowest position. Turn ignition switch OFF 3. Ground temperature gauge sending unit connector Pin 3. Turn ignition switch ON. The temperature gauge should be at its highest position. After the seat belt lamp goes out, the cluster should chime for about Eight Seconds. a. If OK, check temperature sending unit connector for proper connection. If connections are OK, replace the sending unit. b. If not OK, and the high temperature chime sounds but the gauge shows cold, replace the gauge assembly If gauge is still not working, replace the printed circuit board. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T > Component Information > Service and Repair Transmission Mode Indicator - A/T: Service and Repair REMOVAL Floor Console With Transmission Range Indicator 1. Raise the floor console. 2. Remove the attaching screw from each of the two forward cup holders of the floor console. Remove the screws at the rear of the console or inside of the armrest console bin. 3. Pull the parking brake lever all the way up. 4. Lift the floor console at the rear high enough to gain access to the lamp and socket. 5. Remove the indicator lamp socket from bezel to replace the lamp. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Specifications Backup Lamp Switch: Specifications Mounting .............................................................................................................................................. .................................................... 24 Nm (18 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Specifications > Page 6397 Backup Lamp Switch: Testing and Inspection The park/neutral starting switch is the center terminal of the three terminal switch. It provides ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > Automatic Transmission Backup Lamp Switch: Service and Repair Automatic Transmission REMOVAL Unscrew switch from transaxle case allowing fluid to drain into a container. Move selector lever to PARK, then to NEUTRAL position, and inspect to see the switch operating lever fingers are centered in switch opening. INSTALLATION 1. Screw the switch with a new seal into transaxle case and tighten to 33 Nm (24 ft. lbs.). Retest switch with the test lamp. 2. Add fluid to transaxle to bring up to proper level. 3. The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 4. To test switch, remove wiring connector from switch and test for continuity between the two outside pins. 5. Continuity should exist only with transaxle in REVERSE position. 6. No continuity should exist from either pin to the case. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > Automatic Transmission > Page 6400 Backup Lamp Switch: Service and Repair Manual Transmission NOTE: The back-up lamp switch is located on the top left front side of the transaxle case. REMOVAL 1. Lift vehicle on hoist. 2. From bottom side of vehicle, remove wiring connector from switch. 3. Unscrew switch from transaxle. INSTALLATION 1. To install, reverse removal procedure. Teflon tape or equivalent must be used on switch threads. CAUTION: Do not overtighten switch. 2. Confirm back-up lamps are functioning properly following installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information > Service and Repair Backup Light Bulb: Service and Repair REMOVAL 1. Release trunk latch and open trunk lid. 2. Separate trunk lining from rear closure panel to gain access to back of tail lamp. Tail And Stop Lamp Bulb 3. Rotate and remove bulb socket from tail lamp through openings in rear closure panel. 4. Pull bulb from socket. INSTALLATION 1. Push bulb into socket. 2. Rotate and install bulb socket into tail lamp through openings in rear closure panel. 3. Install trunk lining to rear closure panel. 4. Close and secure trunk lid. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair Brake Light Bulb: Service and Repair REMOVAL 1. Release trunk latch and open trunk lid. 2. Separate trunk lining from rear closure panel to gain access to back of tail lamp. Tail And Stop Lamp Bulb 3. Rotate and remove bulb socket from tail lamp through openings in rear closure panel. 4. Pull bulb from socket. INSTALLATION 1. Push bulb into socket. 2. Rotate and install bulb socket into tail lamp through openings in rear closure panel. 3. Install trunk lining to rear closure panel. 4. Close and secure trunk lid. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service Precautions Brake Light Switch: Service Precautions CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Switch Operation Brake Light Switch: Description and Operation Switch Operation The stop lamp switch controls operation of the vehicles stop lamps. Also, if the vehicle is equipped with speed control, the stop lamp switch will deactivate speed control when the brake pedal is depressed. The stop lamp switch controls operation of the right and left tail, stop and turn signal lamp and Center High Mounted Stop Lamp CHMSL, by supplying battery current to these lamps. The stop lamp switch controls the lamp operation by opening and closing the electrical circuit to the stop lamps. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Switch Operation > Page 6413 Brake Light Switch: Description and Operation System Operation SYSTEM OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The switch is mounted in the same location as the conventional stop lamp switch, on the brake pedal mounting bracket under the instrument panel. The PCM monitors the state of the dual function stop lamp switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 6414 Brake Light Switch: Testing and Inspection Fig. 21 Stop Lamp Switch 1. Remove the stop lamp switch, refer to Lighting and Horns/Brake Light Switch/Stop Switch Removal/Installation. Disconnect connector from stop lamp switch. Using an ohmmeter, switch continuity may be checked as follows: 2. With switch plunger released, there should be continuity between Pin 5 and Pin 6. 3. With switch plunger depressed, there should be continuity: - Between Pin 1 and Pin 2. - Between Pin 3 and Pin 4. 4. If the above results are not obtained, the stop lamp switch is defective or out of adjustment. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 6415 Brake Light Switch: Adjustments Stop Light Switch Location In Vehicle PROCEDURE 1. Remove stop lamp switch from its bracket by rotating it approximately 30° in a counter-clockwise direction. 2. Disconnect wiring harness connector from stop lamp switch. 3. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position. 4. Install the stop lamp switch into the bracket using the following procedure. Depress the brake pedal as far down as possible. Then while keeping the brake pedal depressed, install the stop lamp switch into the bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When switch is fully installed in the square hole of the bracket, rotate switch clockwise approximately 30° to lock the switch into the bracket. CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result. 5. Connect the wiring harness connector to the stop lamp switch. 6. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 6416 Brake Light Switch: Service and Repair Stop Light Switch Location In Vehicle REMOVE 1. Depress and hold the brake pedal while rotating stop lamp switch in a counter-clockwise direction approximately 30°. 2. Pull the switch rearward and remove from its mounting bracket. 3. Disconnect wiring harness connector from stop lamp switch. INSTALL NOTE: Prior to installing stop lamp switch into bracket, the plunger must be moved to its fully extended position using procedure in step Step 1. 1. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position. 2. Connect the wiring harness connector to the stop lamp switch. 3. Mount the stop lamp switch into the bracket using the following procedure. Depress the brake pedal as far down as possible. Then install switch in bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When switch is fully installed in bracket, rotate switch clockwise approximately 30° to lock switch into bracket. CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If too much force is used, damage to the stop lamp switch or striker can result. 4. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > Rear Cargo Lamp Cargo Lamp: Service and Repair Rear Cargo Lamp REMOVAL 1. Insert a trim stick or small flat blade between the lamp lens and rear shelf reinforcement panel. 2. Pry the lamp lens downward. 3. Disengage wire connectors. 4. Separate lamp from vehicle. INSTALLATION - Reverse the removal procedure. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > Rear Cargo Lamp > Page 6421 Cargo Lamp: Service and Repair Rear Cargo Lamp Bulb The trunk lamp snaps into the rear shelf panel reinforcement under/below the package shelf. REMOVAL 1. Insert a trim stick or small flat blade between the lamp lens and rear shelf reinforcement panel. 2. Pry the lamp lens downward. 3. Pull bulb from socket INSTALLATION 1. Push bulb into socket. 2. Position the lamp in the rear shelf reinforcement panel and snap into place. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Center High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair Center Mounted Brake Lamp Bulb: Service and Repair REMOVAL 1. Release trunk latch and open trunk lid. CHMSL Bulb 2. Remove bulb socket from center high mounted stop lamp. 3. Pull bulb from socket. INSTALLATION - Reverse the preceding operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Description and Operation Glove Box Lamp: Description and Operation CIRCUIT OPERATION The glove box lamp receives power on the M1 circuit from the 10 Amp fuse located in the Power Distribution Center (PDC). A switch, wired in series after the lamp, CLOSES when the glove box door is opened, and completes a path to ground on the Z3 circuit. The Z3 circuit is spliced in with the ash receiver lamp, PRNDL lamp, and the time delay relay. The Z3 circuit terminates at the instrument panel left center support. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Description and Operation > Page 6430 Glove Box Lamp: Service and Repair Glove Box Switch/Lamp REMOVAL 1. Disconnect battery negative cable and isolate it or remove fuse 12 prior to removing the switch, or wires may short to ground. 2. Open the glove box and push the glove box sides inward allowing the door bumpers to clear and the box to tip forward. 3. Reach inside the opening and squeeze the lamp/switch retainers until they are disengage. 4. Pull the switch/lamp rearward and remove it. Replace the lamp. To replace the switch disconnect wire and replace the switch. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair REMOVAL 1. Disconnect battery negative cable and isolate it or remove fuse 12 prior to removing the switch, or wires may short to ground. 2. Open the glove box and push the glove box sides inward allowing the door bumpers to clear and the box to tip forward. 3. Reach inside the opening and squeeze the lamp/switch retainers until they are disengage. 4. Pull the switch/lamp rearward and remove it. Replace the lamp. To replace the switch disconnect wire and replace the switch. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations DRL Module The Daytime Running Lamp module is attached to a support brace on the underside of the instrument panel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 6438 Daytime Running Lamp Control Unit: Description and Operation CIRCUIT OPERATION - CANADA On vehicles built for sale in Canada, the head- lamps operate, at reduced intensity, when the ignition switch is in the RUN position and the parking brake switch is OPEN. In the Power Distribution Center (PDC), a bus bar connected to battery voltage feeds circuit A1. In the RUN position, the ignition switch connects circuit A1 to circuit A21. A 30 Amp fuse in the PDC, protects circuits A1 and A21. Circuit A21 connects to a bus bar in the fuse block. The bus bar in the fuse block feeds circuit G5 through a 5 Amp fuse in cavity 11. Circuit G5 is powered only when the ignition switch is in the RUN position. Circuit G9 connects to the DRL module. The G9 circuit splices to the brake warning switch, park brake switch and instrument cluster brake warning bulb. Circuit L20 from the headlamp and dimmer switch supplies battery voltage to the DRL module at all times. Circuit A3 from the PDC feeds circuit L20. A 40 Amp fuse in the PDC protects the A3 circuit. From the DRL module, circuit L4 powers the LOW beams of the left and right headlamps. The DRL controls the power to circuit L4. Circuit L4 connects to cavity 10 of the DRL module. Circuit L3 feeds the high beams of the headlamps. When the operator flashes the headlamps with the stalk of the multi-function switch, the DRL senses voltage on circuit L3. When it senses voltage on circuit L3, the DRL module stops supplying power to the low beams on circuit L4. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 6439 Daytime Running Lamp Control Unit: Testing and Inspection - If the park brake switch is CLOSED, the DRL will not turn on the headlamps. The DRL senses if the park brake switch is CLOSED on circuit G9. - Circuit Z1 provides ground for the headlamps. - Circuit L20 of the headlamp switch connector has a jumper that feeds the DRL module. - Check for a blown fuse in circuits A1 or G5. - The headlamp switch has a 24 Amp circuit breaker that feeds circuit L20. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Description and Operation Battery Discharge Protection Relay: Description and Operation Halo Lamp/Time Delay Relay CIRCUIT OPERATION The time delay relay is used to allow a time-ON function for the ignition switch halo lamp. Power for the relay is received on the M1 circuit from the 10 Amp fuse located in the Power Distribution Center (PDC). This is the Ignition-Off Draw (IOD) fuse and HOT at all times. When a door is OPENED, or the headlamp switch is moved to the dome lamp position, a ground path is provided for the relay on the M23 circuit. This energizes the relay, CLOSING the contacts. When the relay contacts are CLOSED, power is provided through the relay to the M50 circuit. The M50 circuit supplies current to the ignition switch lamp in the steering column. Ground for the lamp is provided on the Z3 circuit. This circuit splices with the glove box lamp, the ash receiver lamp, and the PRNDL lamp. The Z3 circuit terminates at the instrument panel left center support. Circuit M23 is also spliced with the Remote Key-less Entry (RKE) module and the time out relay located in the fuse block. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair Dome Lamp Bulb: Service and Repair REMOVAL 1. Insert a trim stick between the headliner and dome lamp lens. 2. Carefully pry downward on the four corners of the lamp lens. 3. Separate lamp lens from lamp. 4. Grasp bulb and pull from lamp socket. INSTALLATION 1. Position bulb in socket and snap into place. 2. Position lens on lamp and snap into place. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: Customer Interest Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 6455 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: All Technical Service Bulletins Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 6461 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair Fog/Driving Lamp Bulb: Service and Repair REMOVAL 1. Remove fog lamp from behind fascia. 2. Disengage wire connector from fog lamp bulb base. Fog Lamp Bulb 3. Remove bulb from lamp. INSTALLATION CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced bulb life will result. - Reverse the preceding operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Power Distribution Center Relay Locations Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Testing and Inspection Fog/Driving Lamp Switch: Testing and Inspection 1. Remove the fog lamp switch. 2. Using two jumper wires, connect Pin 2 and Pin 4 of the switch to battery voltage. Fog Lamp Switch Test Fog Lamp Switch Circuit 3. Using a test lamp, connect the test lamp to Pin 3 as shown in for fog lamp switch circuit. 4. Push the fog lamp switch button. The test lamp and the LED indicator on the front of the switch should illuminate. 5. If either the LED or the test lamp fails to illuminate, replace the switch. Front Export 1. Remove the fog lamp switch and disconnect the connector at the center stack. Front Fog Lamp Switch Circuit Diagram 2. Using two jumper wires connect Pin L7 to battery voltage, and connect Pin Z03 to ground. 3. Push the fog lamp switch button. The LED indicator on the front of the switch should illuminate. Check Pin L35 with a test lamp for battery voltage. 4. If either the LED or the test lamp fails to illuminate, replace the switch. Rear Export 1. Remove the fog lamp switch. 2. Using two jumper wires connect Pin 2 and Pin 4 of the switch to battery voltage. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Testing and Inspection > Page 6472 Rear Fog Lamp Switch Test 3. Using a test lamp, connect the test lamp to Pin 3 as shown in. 4. Push the fog lamp switch button. The test lamp should illuminate, and the LED indicator on the front of the switch. 5. If either the LED, or the test lamp fails to illuminate, replace the switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Service and Repair > Front Fog Lamp Switch Export Fog/Driving Lamp Switch: Service and Repair Front Fog Lamp Switch Export REMOVAL 1. Disconnect the wire connector in the center stack, EUX left side and RHD right side. 2. Remove the floor console and disconnect the two clips attaching the wire harness from the underside of the floor console. 3. Remove the switch bezel from the floor console. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Service and Repair > Front Fog Lamp Switch Export > Page 6475 Fog/Driving Lamp Switch: Service and Repair Rear Window Defogger and/or Fog Lamp Switch REMOVAL 1. Remove the top cover and cluster bezel assembly. Rear Window Defogger And Fog Lamp Switch 2. Reach in and disengage the left bezel latch and remove assembly. 3. Pull the bezel and switch(s) rearward from the opening and disconnect the wire connector(s). 4. Remove the switch from the bezel. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Service and Repair > Front Fog Lamp Switch Export > Page 6476 Fog/Driving Lamp Switch: Service and Repair Rear Window Defogger and/or Fog Lamp Switch Export REMOVAL 1. Remove the top cover and cluster bezel assembly. Rear Window Defogger And Rear Fog Lamp Switch 2. Reach in and disengage the left bezel latch and remove the assembly. 3. Pull the bezel and switch(s) rearward from the opening and disconnect the wire connector(s). 4. Remove the switch from the bezel. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation > Circuit Operation Hazard Warning Flasher: Description and Operation Circuit Operation CIRCUIT OPERATION Hazard Flashers Circuit L9 from the Power Distribution Center (PDC) supplies battery voltage for the hazard flashers. A 10 Amp fuse in the PDC protects circuit L9. Circuit L9 connects to the multi-function switch. With the hazard flashers ON, the multi-function switch connects circuits L9 and L55. Circuit L55 feeds the combination flashing unit. Circuit Z2 provides ground for the flashing unit. From the flashing unit, circuit L32 connects to the multi-function switch. With the hazard flashers ON, the multi-function switch connects circuit L32 to circuits L60, L61, L62, and L63. Circuit L6O supplies voltage to the right front turn signal/hazard lamp. The L6O circuit splices to the instrument cluster to power the right indicator lamp. Circuit L61 supplies voltage to the left front turn signal/hazard lamp. The L61 circuit splices to the instrument cluster to power the left indicator lamp. Circuit L62 supplies voltage to the right rear turn signal/hazard flasher/stop lamp. Circuit L63 supplies voltage to the left rear turn signal/hazard/flasher/stop lamp. Ground Circuit Circuit Z3 provides ground for the instrument cluster indicator lamps. The termination point for circuit Z3 is the instrument panel left center support. Circuit Z1 provides ground for all the turn signal/hazard lamps, although the it has different grounding points for each circuit. Circuit Z2 provides the ground path for the combination flashing unit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation > Circuit Operation > Page 6482 Hazard Warning Flasher: Description and Operation System Operation SYSTEM OPERATION Combination Flasher The turn signal flasher and the hazard warning flasher are combined into one unit called a combination flasher (combo-flasher). The combo-flasher controls the flashing of the hazard warning system and the turn signal system. An inoperative bulb or incomplete turn signal circuit will cause the flasher rate to double. Combo-Flasher The combo-flasher is located on the fuse block. The combo-flasher is black in color for ease of identification. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation > Page 6483 Hazard Warning Flasher: Testing and Inspection - For the left front turn signal/hazard flasher lamp the Z1 circuit grounding point is the left side of the radiator closure panel. - For the right front turn signal/hazard flasher lamp the Z1 circuit grounding point is in the right fender side shield. - For the left rear turn signal/hazard flasher/stop lamp the Z1 circuit grounding point is in the left rear wheel well. - For the right rear turn signal/hazard flasher/ stop lamp the Z1 circuit grounding point is in the right rear wheel well. - Circuit Z1 also supplies ground for the headlamps, parking lamps, rear license plate lamp, back-up lamps and side marker lamps. - The grounding point for circuit Z2 is the instrument panel right center support. Circuit Z2 supplies ground for the combination flashing unit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection Hazard Warning Switch: Testing and Inspection The multi-function switch contains electrical circuitry for turn signal, hazard warning, headlamp beam select, headlamp optical horn. This integrated switch assembly is mounted to the left hand side of the steering column. Should any function of the switch fail, the entire switch assembly must be replaced. Turn Signal And Hazard Switch Continuity Beam Select Switch Continuity To test the switch, first disconnect the negative battery cable, then remove the upper and lower column shrouds to gain access to the switch connector. Remove switch connector. Using an ohmmeter, test for continuity (no resistance) between the terminals of the switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Page 6487 Hazard Warning Switch: Service and Repair REMOVAL 1. Disconnect battery negative cable. 2. Remove both upper and lower steering column shrouds. Multi-Function Switch 3. Remove multi-function switch mounting screws. INSTALLATION For installation, reverse the above procedures. - Tighten multi-function switch to column retaining screws to 2 N.m (17 in. lbs.) torque. - Tighten steering column cover retaining screws to 2 N.m (17 in. lbs.) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. Disengage wire connector from headlamp bulb connector. 3. Remove retaining ring holding bulb to back of headlamp module. Headlamp Bulb 4. Pull bulb from back of headlamp module. INSTALLATION CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced bulb life will result. - Reverse the preceding operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Service and Repair Headlamp Control Module: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. From behind bumper fascia, remove bolt holding outboard end of module to fender. 3. Loosen bolts holding inboard end of module to radiator closure panel. 4. Remove bolt holding grille to headlamp module. Headlamp Module 5. Remove bolts holding top of module to upper cross member. 6. Disengage wire connector from headlamp and parking lamp sockets. 7. Separate headlamp module from vehicle. INSTALLATION - Reverse the preceding operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation Headlamp Switch: Description and Operation CIRCUIT OPERATION In OFF or Parking Lamp Position Circuit A3 originates in the Power Distribution Center (PDC) and supplies battery voltage for the headlamp switch. A 40 Amp fuse protects the A3 circuit. The headlamp switch has an internal 24 Amp circuit breaker that connects circuit A3 to either the L2 or L20 circuits, depending on switch position. In the OFF and PARK positions the headlamp switch feeds the L20 circuit that connects to the multi-function switch. Circuit L20 powers the high beam circuit when the operator flashes the headlamps with the turn signal stalk of the multi-function switch. when the operator flashes the headlamps with the stalk, the multi-function switch connects the L20 circuit to the L3 circuit. The L3 circuit feeds the high beam of the headlamps. In ON Position When the headlamp switch is in the ON position, it connects the A3 circuit from the PDC to circuit L2. Circuit L2 connects to the multi-function switch and feeds the L4 circuit (for low beam operation). The L4 circuit connects to a bus bar in the fuse block. Circuits L43 and L44 connect to the bus bar in fuse block and power the low beam headlamps. Circuit L43 supplies voltage to the left headlamp. Circuit L44 supplies voltage to the right headlamp. Both the L43 and L44 circuits have separate 10 Amp fuses located in fuse block. Fuse 17 protects circuit L43, and fuse 18 protects circuit L44. When the operator selects high beam operation with the turn signal stalk of the multi-function switch, circuit L2 connects to the L3 circuit, Circuit L3 powers high beam operation. On vehicles equipped with Remote Keyless Entry (RKE) the L4 circuit is spliced to the RKE module. The RKE module uses this circuit to flash the headlamps when the operator has activated the PANIC mode with the key fob. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and Inspection > Headlamp Leveling Switch Headlamp Switch: Testing and Inspection Headlamp Leveling Switch 1. Remove the headlamp leveling switch from the instrument panel and disconnect the wire harness connector from the switch. 2. If the L.E.D. is not illuminated, using a voltmeter, connect B+ lead to Pin 4 of the Wire harness connector. Connect the negative lead to Pin 3. Turn ON the headlamp switch to the low beam position and ensure the instrument panel dimmer switch is on day light driving position. If voltage is present, replace switch. If no voltage, connect the ground lead to a good ground, if voltage, repair Pin 3 ground circuit as necessary, and if no voltage. 3. Using a voltmeter, connect B+ lead to Pin 2 of the Wire harness connector. Connect the negative lead to Pin 3. Turn ON the headlamp switch to the low beam position. If battery voltage, go to Step 5. If not OK, go to Step 4. 4. Connect the ground lead to a good ground, if no voltage, refer to Wiring Diagrams and test circuit back to headlamp switch. If battery voltage, repair Pin 3 ground circuit as necessary 5. Turn headlamps OFF. Connect the wire harness connector to the headlamp leveling switch. Turn ON the headlamp switch to the low. beam position. Check voltage at Pin 5, while rotating the headlamp leveling switch knob through the four positions. The voltage reading should change as the switch is rotated to each position. If the voltage does not vary replace switch. If OK, test the headlamp leveling motors and/or circuit to the motors. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and Inspection > Headlamp Leveling Switch > Page 6500 Headlamp Switch: Testing and Inspection Headlamp Switch Test Headlamp Switch Test 1. Remove the headlamp switch. 2. Use a ohmmeter, and check continuity between the terminals of the switch as shown in the Headlamp Switch Test. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Headlamp Leveling Switch Export Headlamp Switch: Service and Repair Headlamp Leveling Switch Export REMOVAL 1. Remove the top cover and cluster bezel assembly Headlamp Leveling Switch 2. Disengage the headlamp leveling switch bezel from instrument panel . 3. Pull the switch and bezel rearward from the opening and disconnect the wire connector. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Headlamp Leveling Switch Export > Page 6503 Headlamp Switch: Service and Repair Headlight Switch REMOVAL 1. Remove the steering column cover and liner. Headlamp Switch 2. Remove the three screws securing headlamp switch mounting plate to the instrument panel. 3. Pull the headlamp switch and mounting plate rearward from the instrument panel opening. 4. Disconnect both the nine way and the ground wiring connectors from the switch. 5. Remove the switch knob by depressing the release button on the bottom on the switch and pulling out knob from switch. 6. Snap headlamp switch bezel out of mounting plate to gain access to the mounting plate retaining nut. 7. Remove the headlamp switch, mounting plate retaining nut and separate switch from mounting plate. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Description and Operation Hi-Beam Indicator Lamp: Description and Operation CIRCUIT OPERATION The High Beam Indicator Lamp is used to indicate to the operator that the high beam headlamps are ON. Power is supplied to the cluster on the L3 circuit for vehicles without Daytime Running Lamps (DRL), or the G34 circuit for vehicles with DRL. Ground is provided on the Z3 circuit. On vehicle equipped without DRL circuit L3 connects from the headlamp dimmer switch to the instrument cluster. On vehicles with DRL circuit G34 connects from the DRL module to the instrument cluster. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Component Locations Power Distribution Center (Top) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Component Locations > Page 6512 Auto Shutdown Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6513 Horn Relay: Diagrams Power Distribution Center (Bottom) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6514 Power Distribution Center (Top) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6515 Horn Relay: Testing and Inspection 1. Remove horn relay. 2. Using ohmmeter, test for continuity between ground and circuit 65 of horn relay. a. When the horn switch is not depressed, no continuity should be present. b. Continuity to ground when horn switch is depressed. c. If continuity is not correct repair horn switch or wiring as necessary. 3. Insert a jumper wire between circuit 63 and 66 of the Power Distribution Center. a. If horn sounds replace relay. b. If the horn does not sound, install horn relay and refer to Horn Test. 4. Using voltmeter, test voltage at: a. Circuit 62 and 66 test for battery voltage from fuse C to body ground. b. If voltage is incorrect repair as necessary. 5. Check relay for 70 to 75 Ohms resistance from terminal 85 to 86. If resistance not OK, replace relay. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6516 Horn Relay: Service and Repair REMOVAL 1. Remove the Power Distribution Center cover and locate the horn relay. Power Distribution Center 2. Remove the horn relay. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Description and Operation Horn Switch: Description and Operation Horn Switch The horn switch is mounted between the outer and inner cover of the Driver Airbag Module. When the Driver Airbag is pressed the horn switch makes contact to ground. The ground signal is carried to the horn relay and the horn sounds. 1. The horn switch grounds to the airbag housing. 2. If horn does not sound check for corrosion: - Horn wire - Horn switch ground connected to airbag metal housing - Airbag to steering wheel - Ensure horn wire is properly connected and insulator is in place on wire. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Description and Operation > Page 6520 Horn Switch: Testing and Inspection 1. Remove horn relay from the Power Distribution Center. Power Distribution Center 2. Using ohmmeter, connect one lead to ground and the other lead to cavity 65 of the power distribution center. 3. Depress horn switch, should have continuity. If no continuity go to Step 4. 4. Test continuity at horn switch remove the Driver Airbag Module. Refer to Air Bags and Seat Belts/Air Bag Control Module/Replacement/Driver Airbag Module. Test Horn Switch Driver Airbag Module 5. Using ohmmeter, connect one lead to the airbag module ground and the other lead to B+ wire. 6. Depress horn switch, and the meter should show continuity. If no continuity, replace the Driver Airbag Module. If OK, repair as necessary. . Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Description and Operation > Page 6521 Horn Switch: Service and Repair The Horn Switch is part of the Driver Airbag Module. Refer to Air Bags and Seat Belts/Air Bag Control Module/Replacement. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Description and Operation Interior Lighting Relay: Description and Operation CIRCUIT OPERATION The time out relay is located in the fuse block and is used to control the ground path for various interior lamps. It will also turn the lamps OFF after a specified period of time, and works with the Remote Keyless Entry (RKE) system for illuminated entry. Circuit M2 connects to the relay and supplied a ground path through the door ajar switches. Circuit M1 is used to supply battery voltage to the relay. This circuit is produced by a 10 Amp fuse located in cavity 13 of the Power Distribution Center (PDC). Circuit M32 is connected from the relay to the various interior lamps and RKE module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Description and Operation Key Cylinder Lamp: Description and Operation CIRCUIT OPERATION The time delay relay is used to allow a time-ON function for the ignition switch halo lamp. Power for the relay is received on the M1 circuit from the 10 Amp fuse located in the Power Distribution Center (PDC). This is the Ignition-Off Draw (IOD) fuse and HOT at all times. When a door is OPENED, or the headlamp switch is moved to the dome lamp position, a ground path is provided for the relay on the M23 circuit. This energizes the relay, CLOSING the contacts. When the relay contacts are CLOSED, power is provided through the relay to the M50 circuit. The M50 circuit supplies current to the ignition switch lamp in the steering column. Ground for the lamp is provided on the Z3 circuit. This circuit splices with the glove box lamp, the ash receiver lamp, and the PRNDL lamp. The Z3 circuit terminates at the instrument panel left center support. Circuit M23 is also spliced with the Remote Key-less Entry (RKE) module and the time out relay located in the fuse block. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Description and Operation > Page 6528 Key Cylinder Lamp: Service and Repair Ignition Key Lamp REMOVAL 1. Remove the steering column cover. 2. Disconnect the lamp hood from the base panel. 3. Remove the lamp socket from hood and replace the lamp. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair License Plate Bulb: Service and Repair REMOVAL License Plate Lamp 1. Remove screws holding license plate lamp to rear bumper. 2. Separate lamp from bumper. 3. Remove bulb socket from lamp. 4. Pull bulb from socket. INSTALLATION - Reverse the preceding operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Component Information > Description and Operation Map Light: Description and Operation MAP/Reading Lamps CIRCUIT OPERATION The map/reading lamps are powered by the M1 circuit from the Power Distribution Center (PDC). This circuit is the Ignition-Off Draw circuit and protected by a 10 Amp fuse. The M1 circuit is spliced and provides power for the visor/vanity lamps, radio, power mirrors, dome lamp, time delay relay, and other interior lamps. Ground for the lamps is provided from two sources. One is the Z3 circuit which is spliced in with the glove box lamp and terminates at the instrument panel left center support. The second ground is provided on circuit M23. This circuit is spliced in with the time out relay so the lamps will turn ON when any door is OPENED. On vehicles equipped with Remote Keyless Entry (RKE) the M23 circuit, which is the ground circuit when a door is OPENED, is connected to the RKE module. The module will provide a ground path for the lamps with a valid signal from the transmitter. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair Marker Lamp Bulb: Service and Repair REMOVAL 1. Reach behind front bumper fascia forward of front wheel. 2. Remove socket from side marker lamp. Front Side Marker 3. Pull bulb from socket. INSTALLATION - Reverse the preceding operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair Parking Light Bulb: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. Remove screws holding park and turn signal lamp to headlamp module. 3. Separate lamp from module. 4. Remove bulb socket from back of lamp. Park And Turn Signal Lamp Bulb 5. Pull bulb from socket. INSTALLATION - Reverse the preceding operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Description and Operation Battery Discharge Protection Relay: Description and Operation Halo Lamp/Time Delay Relay CIRCUIT OPERATION The time delay relay is used to allow a time-ON function for the ignition switch halo lamp. Power for the relay is received on the M1 circuit from the 10 Amp fuse located in the Power Distribution Center (PDC). This is the Ignition-Off Draw (IOD) fuse and HOT at all times. When a door is OPENED, or the headlamp switch is moved to the dome lamp position, a ground path is provided for the relay on the M23 circuit. This energizes the relay, CLOSING the contacts. When the relay contacts are CLOSED, power is provided through the relay to the M50 circuit. The M50 circuit supplies current to the ignition switch lamp in the steering column. Ground for the lamp is provided on the Z3 circuit. This circuit splices with the glove box lamp, the ash receiver lamp, and the PRNDL lamp. The Z3 circuit terminates at the instrument panel left center support. Circuit M23 is also spliced with the Remote Key-less Entry (RKE) module and the time out relay located in the fuse block. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations DRL Module The Daytime Running Lamp module is attached to a support brace on the underside of the instrument panel. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 6551 Daytime Running Lamp Control Unit: Description and Operation CIRCUIT OPERATION - CANADA On vehicles built for sale in Canada, the head- lamps operate, at reduced intensity, when the ignition switch is in the RUN position and the parking brake switch is OPEN. In the Power Distribution Center (PDC), a bus bar connected to battery voltage feeds circuit A1. In the RUN position, the ignition switch connects circuit A1 to circuit A21. A 30 Amp fuse in the PDC, protects circuits A1 and A21. Circuit A21 connects to a bus bar in the fuse block. The bus bar in the fuse block feeds circuit G5 through a 5 Amp fuse in cavity 11. Circuit G5 is powered only when the ignition switch is in the RUN position. Circuit G9 connects to the DRL module. The G9 circuit splices to the brake warning switch, park brake switch and instrument cluster brake warning bulb. Circuit L20 from the headlamp and dimmer switch supplies battery voltage to the DRL module at all times. Circuit A3 from the PDC feeds circuit L20. A 40 Amp fuse in the PDC protects the A3 circuit. From the DRL module, circuit L4 powers the LOW beams of the left and right headlamps. The DRL controls the power to circuit L4. Circuit L4 connects to cavity 10 of the DRL module. Circuit L3 feeds the high beams of the headlamps. When the operator flashes the headlamps with the stalk of the multi-function switch, the DRL senses voltage on circuit L3. When it senses voltage on circuit L3, the DRL module stops supplying power to the low beams on circuit L4. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 6552 Daytime Running Lamp Control Unit: Testing and Inspection - If the park brake switch is CLOSED, the DRL will not turn on the headlamps. The DRL senses if the park brake switch is CLOSED on circuit G9. - Circuit Z1 provides ground for the headlamps. - Circuit L20 of the headlamp switch connector has a jumper that feeds the DRL module. - Check for a blown fuse in circuits A1 or G5. - The headlamp switch has a 24 Amp circuit breaker that feeds circuit L20. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Power Distribution Center Relay Locations Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Service and Repair Headlamp Control Module: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. From behind bumper fascia, remove bolt holding outboard end of module to fender. 3. Loosen bolts holding inboard end of module to radiator closure panel. 4. Remove bolt holding grille to headlamp module. Headlamp Module 5. Remove bolts holding top of module to upper cross member. 6. Disengage wire connector from headlamp and parking lamp sockets. 7. Separate headlamp module from vehicle. INSTALLATION - Reverse the preceding operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Component Locations Power Distribution Center (Top) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Component Locations > Page 6563 Auto Shutdown Relay Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6564 Horn Relay: Diagrams Power Distribution Center (Bottom) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6565 Power Distribution Center (Top) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6566 Horn Relay: Testing and Inspection 1. Remove horn relay. 2. Using ohmmeter, test for continuity between ground and circuit 65 of horn relay. a. When the horn switch is not depressed, no continuity should be present. b. Continuity to ground when horn switch is depressed. c. If continuity is not correct repair horn switch or wiring as necessary. 3. Insert a jumper wire between circuit 63 and 66 of the Power Distribution Center. a. If horn sounds replace relay. b. If the horn does not sound, install horn relay and refer to Horn Test. 4. Using voltmeter, test voltage at: a. Circuit 62 and 66 test for battery voltage from fuse C to body ground. b. If voltage is incorrect repair as necessary. 5. Check relay for 70 to 75 Ohms resistance from terminal 85 to 86. If resistance not OK, replace relay. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6567 Horn Relay: Service and Repair REMOVAL 1. Remove the Power Distribution Center cover and locate the horn relay. Power Distribution Center 2. Remove the horn relay. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Description and Operation Interior Lighting Relay: Description and Operation CIRCUIT OPERATION The time out relay is located in the fuse block and is used to control the ground path for various interior lamps. It will also turn the lamps OFF after a specified period of time, and works with the Remote Keyless Entry (RKE) system for illuminated entry. Circuit M2 connects to the relay and supplied a ground path through the door ajar switches. Circuit M1 is used to supply battery voltage to the relay. This circuit is produced by a 10 Amp fuse located in cavity 13 of the Power Distribution Center (PDC). Circuit M32 is connected from the relay to the various interior lamps and RKE module. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications Backup Lamp Switch: Specifications Mounting .............................................................................................................................................. .................................................... 24 Nm (18 ft. lbs.) Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications > Page 6575 Backup Lamp Switch: Testing and Inspection The park/neutral starting switch is the center terminal of the three terminal switch. It provides ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. 1. To test switch, remove wiring connector from switch and test for continuity between center pin of switch and transaxle case. Continuity should exist only when transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Automatic Transmission Backup Lamp Switch: Service and Repair Automatic Transmission REMOVAL Unscrew switch from transaxle case allowing fluid to drain into a container. Move selector lever to PARK, then to NEUTRAL position, and inspect to see the switch operating lever fingers are centered in switch opening. INSTALLATION 1. Screw the switch with a new seal into transaxle case and tighten to 33 Nm (24 ft. lbs.). Retest switch with the test lamp. 2. Add fluid to transaxle to bring up to proper level. 3. The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 4. To test switch, remove wiring connector from switch and test for continuity between the two outside pins. 5. Continuity should exist only with transaxle in REVERSE position. 6. No continuity should exist from either pin to the case. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Automatic Transmission > Page 6578 Backup Lamp Switch: Service and Repair Manual Transmission NOTE: The back-up lamp switch is located on the top left front side of the transaxle case. REMOVAL 1. Lift vehicle on hoist. 2. From bottom side of vehicle, remove wiring connector from switch. 3. Unscrew switch from transaxle. INSTALLATION 1. To install, reverse removal procedure. Teflon tape or equivalent must be used on switch threads. CAUTION: Do not overtighten switch. 2. Confirm back-up lamps are functioning properly following installation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service Precautions Brake Light Switch: Service Precautions CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Switch Operation Brake Light Switch: Description and Operation Switch Operation The stop lamp switch controls operation of the vehicles stop lamps. Also, if the vehicle is equipped with speed control, the stop lamp switch will deactivate speed control when the brake pedal is depressed. The stop lamp switch controls operation of the right and left tail, stop and turn signal lamp and Center High Mounted Stop Lamp CHMSL, by supplying battery current to these lamps. The stop lamp switch controls the lamp operation by opening and closing the electrical circuit to the stop lamps. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Switch Operation > Page 6584 Brake Light Switch: Description and Operation System Operation SYSTEM OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The switch is mounted in the same location as the conventional stop lamp switch, on the brake pedal mounting bracket under the instrument panel. The PCM monitors the state of the dual function stop lamp switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 6585 Brake Light Switch: Testing and Inspection Fig. 21 Stop Lamp Switch 1. Remove the stop lamp switch, refer to Lighting and Horns/Brake Light Switch/Stop Switch Removal/Installation. Disconnect connector from stop lamp switch. Using an ohmmeter, switch continuity may be checked as follows: 2. With switch plunger released, there should be continuity between Pin 5 and Pin 6. 3. With switch plunger depressed, there should be continuity: - Between Pin 1 and Pin 2. - Between Pin 3 and Pin 4. 4. If the above results are not obtained, the stop lamp switch is defective or out of adjustment. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 6586 Brake Light Switch: Adjustments Stop Light Switch Location In Vehicle PROCEDURE 1. Remove stop lamp switch from its bracket by rotating it approximately 30° in a counter-clockwise direction. 2. Disconnect wiring harness connector from stop lamp switch. 3. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position. 4. Install the stop lamp switch into the bracket using the following procedure. Depress the brake pedal as far down as possible. Then while keeping the brake pedal depressed, install the stop lamp switch into the bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When switch is fully installed in the square hole of the bracket, rotate switch clockwise approximately 30° to lock the switch into the bracket. CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result. 5. Connect the wiring harness connector to the stop lamp switch. 6. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 6587 Brake Light Switch: Service and Repair Stop Light Switch Location In Vehicle REMOVE 1. Depress and hold the brake pedal while rotating stop lamp switch in a counter-clockwise direction approximately 30°. 2. Pull the switch rearward and remove from its mounting bracket. 3. Disconnect wiring harness connector from stop lamp switch. INSTALL NOTE: Prior to installing stop lamp switch into bracket, the plunger must be moved to its fully extended position using procedure in step Step 1. 1. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position. 2. Connect the wiring harness connector to the stop lamp switch. 3. Mount the stop lamp switch into the bracket using the following procedure. Depress the brake pedal as far down as possible. Then install switch in bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When switch is fully installed in bracket, rotate switch clockwise approximately 30° to lock switch into bracket. CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If too much force is used, damage to the stop lamp switch or striker can result. 4. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection Combination Switch: Testing and Inspection The multi-function switch contains electrical circuitry for turn signal, hazard warning, headlamp beam select, headlamp optical horn. This integrated switch assembly is mounted to the left hand side of the steering column. Should any function of the switch fail, the entire switch assembly must be replaced. Turn Signal And Hazard Switch Continuity Beam Select Switch Continuity To test the switch, first disconnect the negative battery cable, then remove the upper and lower column shrouds to gain access to the switch connector. Remove switch connector. Using an ohmmeter, test for continuity (no resistance) between the terminals of the switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 6591 Combination Switch: Service and Repair REMOVAL 1. Disconnect battery negative cable. 2. Remove both upper and lower steering column shrouds. Multi-Function Switch 3. Remove multi-function switch mounting screws. INSTALLATION For installation, reverse the above procedures. - Tighten multi-function switch to column retaining screws to 2 N.m (17 in. lbs.) torque. - Tighten steering column cover retaining screws to 2 N.m (17 in. lbs.) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps Improper Operation Door Switch: Customer Interest Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps Improper Operation > Page 6600 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: All Technical Service Bulletins Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 6606 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Testing and Inspection Fog/Driving Lamp Switch: Testing and Inspection 1. Remove the fog lamp switch. 2. Using two jumper wires, connect Pin 2 and Pin 4 of the switch to battery voltage. Fog Lamp Switch Test Fog Lamp Switch Circuit 3. Using a test lamp, connect the test lamp to Pin 3 as shown in for fog lamp switch circuit. 4. Push the fog lamp switch button. The test lamp and the LED indicator on the front of the switch should illuminate. 5. If either the LED or the test lamp fails to illuminate, replace the switch. Front Export 1. Remove the fog lamp switch and disconnect the connector at the center stack. Front Fog Lamp Switch Circuit Diagram 2. Using two jumper wires connect Pin L7 to battery voltage, and connect Pin Z03 to ground. 3. Push the fog lamp switch button. The LED indicator on the front of the switch should illuminate. Check Pin L35 with a test lamp for battery voltage. 4. If either the LED or the test lamp fails to illuminate, replace the switch. Rear Export 1. Remove the fog lamp switch. 2. Using two jumper wires connect Pin 2 and Pin 4 of the switch to battery voltage. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Testing and Inspection > Page 6610 Rear Fog Lamp Switch Test 3. Using a test lamp, connect the test lamp to Pin 3 as shown in. 4. Push the fog lamp switch button. The test lamp should illuminate, and the LED indicator on the front of the switch. 5. If either the LED, or the test lamp fails to illuminate, replace the switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Front Fog Lamp Switch Export Fog/Driving Lamp Switch: Service and Repair Front Fog Lamp Switch Export REMOVAL 1. Disconnect the wire connector in the center stack, EUX left side and RHD right side. 2. Remove the floor console and disconnect the two clips attaching the wire harness from the underside of the floor console. 3. Remove the switch bezel from the floor console. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Front Fog Lamp Switch Export > Page 6613 Fog/Driving Lamp Switch: Service and Repair Rear Window Defogger and/or Fog Lamp Switch REMOVAL 1. Remove the top cover and cluster bezel assembly. Rear Window Defogger And Fog Lamp Switch 2. Reach in and disengage the left bezel latch and remove assembly. 3. Pull the bezel and switch(s) rearward from the opening and disconnect the wire connector(s). 4. Remove the switch from the bezel. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Front Fog Lamp Switch Export > Page 6614 Fog/Driving Lamp Switch: Service and Repair Rear Window Defogger and/or Fog Lamp Switch Export REMOVAL 1. Remove the top cover and cluster bezel assembly. Rear Window Defogger And Rear Fog Lamp Switch 2. Reach in and disengage the left bezel latch and remove the assembly. 3. Pull the bezel and switch(s) rearward from the opening and disconnect the wire connector(s). 4. Remove the switch from the bezel. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair REMOVAL 1. Disconnect battery negative cable and isolate it or remove fuse 12 prior to removing the switch, or wires may short to ground. 2. Open the glove box and push the glove box sides inward allowing the door bumpers to clear and the box to tip forward. 3. Reach inside the opening and squeeze the lamp/switch retainers until they are disengage. 4. Pull the switch/lamp rearward and remove it. Replace the lamp. To replace the switch disconnect wire and replace the switch. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection Hazard Warning Switch: Testing and Inspection The multi-function switch contains electrical circuitry for turn signal, hazard warning, headlamp beam select, headlamp optical horn. This integrated switch assembly is mounted to the left hand side of the steering column. Should any function of the switch fail, the entire switch assembly must be replaced. Turn Signal And Hazard Switch Continuity Beam Select Switch Continuity To test the switch, first disconnect the negative battery cable, then remove the upper and lower column shrouds to gain access to the switch connector. Remove switch connector. Using an ohmmeter, test for continuity (no resistance) between the terminals of the switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 6621 Hazard Warning Switch: Service and Repair REMOVAL 1. Disconnect battery negative cable. 2. Remove both upper and lower steering column shrouds. Multi-Function Switch 3. Remove multi-function switch mounting screws. INSTALLATION For installation, reverse the above procedures. - Tighten multi-function switch to column retaining screws to 2 N.m (17 in. lbs.) torque. - Tighten steering column cover retaining screws to 2 N.m (17 in. lbs.) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation Headlamp Switch: Description and Operation CIRCUIT OPERATION In OFF or Parking Lamp Position Circuit A3 originates in the Power Distribution Center (PDC) and supplies battery voltage for the headlamp switch. A 40 Amp fuse protects the A3 circuit. The headlamp switch has an internal 24 Amp circuit breaker that connects circuit A3 to either the L2 or L20 circuits, depending on switch position. In the OFF and PARK positions the headlamp switch feeds the L20 circuit that connects to the multi-function switch. Circuit L20 powers the high beam circuit when the operator flashes the headlamps with the turn signal stalk of the multi-function switch. when the operator flashes the headlamps with the stalk, the multi-function switch connects the L20 circuit to the L3 circuit. The L3 circuit feeds the high beam of the headlamps. In ON Position When the headlamp switch is in the ON position, it connects the A3 circuit from the PDC to circuit L2. Circuit L2 connects to the multi-function switch and feeds the L4 circuit (for low beam operation). The L4 circuit connects to a bus bar in the fuse block. Circuits L43 and L44 connect to the bus bar in fuse block and power the low beam headlamps. Circuit L43 supplies voltage to the left headlamp. Circuit L44 supplies voltage to the right headlamp. Both the L43 and L44 circuits have separate 10 Amp fuses located in fuse block. Fuse 17 protects circuit L43, and fuse 18 protects circuit L44. When the operator selects high beam operation with the turn signal stalk of the multi-function switch, circuit L2 connects to the L3 circuit, Circuit L3 powers high beam operation. On vehicles equipped with Remote Keyless Entry (RKE) the L4 circuit is spliced to the RKE module. The RKE module uses this circuit to flash the headlamps when the operator has activated the PANIC mode with the key fob. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Headlamp Leveling Switch Headlamp Switch: Testing and Inspection Headlamp Leveling Switch 1. Remove the headlamp leveling switch from the instrument panel and disconnect the wire harness connector from the switch. 2. If the L.E.D. is not illuminated, using a voltmeter, connect B+ lead to Pin 4 of the Wire harness connector. Connect the negative lead to Pin 3. Turn ON the headlamp switch to the low beam position and ensure the instrument panel dimmer switch is on day light driving position. If voltage is present, replace switch. If no voltage, connect the ground lead to a good ground, if voltage, repair Pin 3 ground circuit as necessary, and if no voltage. 3. Using a voltmeter, connect B+ lead to Pin 2 of the Wire harness connector. Connect the negative lead to Pin 3. Turn ON the headlamp switch to the low beam position. If battery voltage, go to Step 5. If not OK, go to Step 4. 4. Connect the ground lead to a good ground, if no voltage, refer to Wiring Diagrams and test circuit back to headlamp switch. If battery voltage, repair Pin 3 ground circuit as necessary 5. Turn headlamps OFF. Connect the wire harness connector to the headlamp leveling switch. Turn ON the headlamp switch to the low. beam position. Check voltage at Pin 5, while rotating the headlamp leveling switch knob through the four positions. The voltage reading should change as the switch is rotated to each position. If the voltage does not vary replace switch. If OK, test the headlamp leveling motors and/or circuit to the motors. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Headlamp Leveling Switch > Page 6627 Headlamp Switch: Testing and Inspection Headlamp Switch Test Headlamp Switch Test 1. Remove the headlamp switch. 2. Use a ohmmeter, and check continuity between the terminals of the switch as shown in the Headlamp Switch Test. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Leveling Switch Export Headlamp Switch: Service and Repair Headlamp Leveling Switch Export REMOVAL 1. Remove the top cover and cluster bezel assembly Headlamp Leveling Switch 2. Disengage the headlamp leveling switch bezel from instrument panel . 3. Pull the switch and bezel rearward from the opening and disconnect the wire connector. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Leveling Switch Export > Page 6630 Headlamp Switch: Service and Repair Headlight Switch REMOVAL 1. Remove the steering column cover and liner. Headlamp Switch 2. Remove the three screws securing headlamp switch mounting plate to the instrument panel. 3. Pull the headlamp switch and mounting plate rearward from the instrument panel opening. 4. Disconnect both the nine way and the ground wiring connectors from the switch. 5. Remove the switch knob by depressing the release button on the bottom on the switch and pulling out knob from switch. 6. Snap headlamp switch bezel out of mounting plate to gain access to the mounting plate retaining nut. 7. Remove the headlamp switch, mounting plate retaining nut and separate switch from mounting plate. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation Horn Switch: Description and Operation Horn Switch The horn switch is mounted between the outer and inner cover of the Driver Airbag Module. When the Driver Airbag is pressed the horn switch makes contact to ground. The ground signal is carried to the horn relay and the horn sounds. 1. The horn switch grounds to the airbag housing. 2. If horn does not sound check for corrosion: - Horn wire - Horn switch ground connected to airbag metal housing - Airbag to steering wheel - Ensure horn wire is properly connected and insulator is in place on wire. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Page 6634 Horn Switch: Testing and Inspection 1. Remove horn relay from the Power Distribution Center. Power Distribution Center 2. Using ohmmeter, connect one lead to ground and the other lead to cavity 65 of the power distribution center. 3. Depress horn switch, should have continuity. If no continuity go to Step 4. 4. Test continuity at horn switch remove the Driver Airbag Module. Refer to Air Bags and Seat Belts/Air Bag Control Module/Replacement/Driver Airbag Module. Test Horn Switch Driver Airbag Module 5. Using ohmmeter, connect one lead to the airbag module ground and the other lead to B+ wire. 6. Depress horn switch, and the meter should show continuity. If no continuity, replace the Driver Airbag Module. If OK, repair as necessary. . Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Page 6635 Horn Switch: Service and Repair The Horn Switch is part of the Driver Airbag Module. Refer to Air Bags and Seat Belts/Air Bag Control Module/Replacement. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair Tail Light Bulb: Service and Repair Tail, Stop, Back-Up and Turn Signal Lamp Bulb REMOVAL 1. Release trunk latch and open trunk lid. 2. Separate trunk lining from rear closure panel to gain access to back of tail lamp. Tail And Stop Lamp Bulb 3. Rotate and remove bulb socket from tail lamp through openings in rear closure panel. 4. Pull bulb from socket. INSTALLATION 1. Push bulb into socket. 2. Rotate and install bulb socket into tail lamp through openings in rear closure panel. 3. Install trunk lining to rear closure panel. 4. Close and secure trunk lid. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Description and Operation Trunk Lamp: Description and Operation CIRCUIT OPERATION The trunk lamp uses a case-grounded switch located on the trunk latch. The switch is normally OPEN. When the deck lid is opened, the switch CLOSES, completing a path to ground on circuit M4. The M1 circuit provides power to the lamp, and is HOT at all times. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Description and Operation > Page 6643 Trunk Lamp: Testing and Inspection - Check the 10 Amp fuse located in the Power Distribution Center (PDC) for the trunk lamp, underhood lamp, visor/vanity lamps, dome lamp, time delay relay, and the glove box lamp. - Check for a good ground at the instrument panel left center support. - Check the door switches for a good ground. - Check the 4 Amp fuse in the fuse block, cavity 12. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Description and Operation > Page 6644 Trunk Lamp: Service and Repair REMOVAL The trunk lamp snaps into the rear shelf panel reinforcement under/below the package shelf. 1. Remove the socket assembly by reaching up above the sheet metal. Push the snap inward and downward and remove the assembly 2. Remove the lamp from socket and pull the socket from the lens. Replace as necessary INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Testing and Inspection Combination Switch: Testing and Inspection The multi-function switch contains electrical circuitry for turn signal, hazard warning, headlamp beam select, headlamp optical horn. This integrated switch assembly is mounted to the left hand side of the steering column. Should any function of the switch fail, the entire switch assembly must be replaced. Turn Signal And Hazard Switch Continuity Beam Select Switch Continuity To test the switch, first disconnect the negative battery cable, then remove the upper and lower column shrouds to gain access to the switch connector. Remove switch connector. Using an ohmmeter, test for continuity (no resistance) between the terminals of the switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Testing and Inspection > Page 6649 Combination Switch: Service and Repair REMOVAL 1. Disconnect battery negative cable. 2. Remove both upper and lower steering column shrouds. Multi-Function Switch 3. Remove multi-function switch mounting screws. INSTALLATION For installation, reverse the above procedures. - Tighten multi-function switch to column retaining screws to 2 N.m (17 in. lbs.) torque. - Tighten steering column cover retaining screws to 2 N.m (17 in. lbs.) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation Turn Signal Flasher: Description and Operation SYSTEM OPERATION Combination Flasher The turn signal flasher and the hazard warning flasher are combined into one unit called a combination flasher (combo-flasher). The combo-flasher controls the flashing of the hazard warning system and the turn signal system. An inoperative bulb or incomplete turn signal circuit will cause the flasher rate to double. Combo-Flasher The combo-flasher is located on the fuse block. The combo-flasher is black in color for ease of identification. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Description and Operation Turn Signal Indicator: Description and Operation Right and Left Turn Signal Indicators CIRCUIT OPERATION These lamps are used to indicate to the operator which turn signal is ON. Power for the lamps comes from the turn signal switch. The L60 circuit is for the right turn indicator, and the L61 circuit is used for the left turn signal indicator. Ground for the circuits is provided on the Z3 circuit. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Park and Turn Signal Lamp Bulb Turn Signal Bulb: Service and Repair Park and Turn Signal Lamp Bulb REMOVAL 1. Release hood latch and open hood. 2. Remove screws holding park and turn signal lamp to headlamp module. 3. Separate lamp from module. 4. Remove bulb socket from back of lamp. Park And Turn Signal Lamp Bulb 5. Pull bulb from socket. INSTALLATION - Reverse the preceding operation. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Park and Turn Signal Lamp Bulb > Page 6661 Turn Signal Bulb: Service and Repair Tail, Stop, Turn Signal and Back-Up Lamp Bulb REMOVAL 1. Release trunk latch and open trunk lid. 2. Separate trunk lining from rear closure panel to gain access to back of tail lamp. Tail And Stop Lamp Bulb 3. Rotate and remove bulb socket from tail lamp through openings in rear closure panel. 4. Pull bulb from socket. INSTALLATION 1. Push bulb into socket. 2. Rotate and install bulb socket into tail lamp through openings in rear closure panel. 3. Install trunk lining to rear closure panel. 4. Close and secure trunk lid. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Light Bulb > Component Information > Service and Repair Underhood Light Bulb: Service and Repair REMOVAL 1. Disconnect the wire harness connector from the underhood lamp. 2. Rotate the bulb counter-clockwise. Remove it from the lamp socket. INSTALLATION 1. Insert the replacement bulb in the lamp base socket and rotate it clockwise. 2. Connect the wire harness connector. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Description and Operation Vanity Lamp: Description and Operation Visor/Vanity Lamps CIRCUIT OPERATION The visor/vanity lamps are case-grounded, and are operated by a switch internal to the assembly Power for the lamps is on the M1 circuit from the Power Distribution Center (PDC). When the operator opens the cover, the switch CLOSES, completing a path to ground illuminating the lamp. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Description and Operation > Page 6669 Vanity Lamp: Service and Repair The visor vanity lamp is incorporated in the visor assembly. Replace the visor if the lamp has failed. REMOVAL 1. Lower visor. 2. Insert a small flat bladed tool between the lamp lens and lamp. 3. Carefully pry lens outward. 4. Remove bulb from socket. INSTALLATION 1. Position bulb in socket and snap into place. 2. Position lens on lamp and snap into place. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Heated Glass Element Switch > Component Information > Description and Operation Heated Glass Element Switch: Description and Operation SYSTEM OPERATION The rear window defogger switch is a control switch and timer relay integrated into a single panel mounted assembly. Actuating the switch energizes the circuit which allows current to flow through the grid lines. Upon initial actuation for approximately eight to ten minutes, or until either the switch or ignition is turned off. An indicating lamp illuminates a lens inlaid in the control switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Heated Glass Element Switch > Component Information > Description and Operation > Page 6675 Heated Glass Element Switch: Testing and Inspection The rear window defogger switch may be tested in- vehicle or bench tested. In vehicle testing is accomplished in the following manner: 1. Remove the switch from the instrument panel but leave the switch connected. 2. Turn the ignition switch ON. Rear Window Defogger Switch Rear Window Defogger Switch-Export 3. Using a voltmeter, check for battery voltage at Pin 3 and Pin 4. a. If OK, go to Step 4. b. If NOT OK, check fuse 8 in fuse block and the 30 Amp maxi fuse in the Power Distribution Center (PDC). If fuses are OK, check wiring circuit. 4. Check Pin 5, with switch in the ON position there should be battery voltage and no voltage in the OFF position. a. If OK, go to Step 5. b. If NOT OK, no voltage in the ON position or voltage in the OFF position. Replace the switch/relay module. 5. Press switch to ON position. The indicator lamp should come on and remain on for approximately 10 minutes. If the indicator lamp fails to light or no voltage is present for approximately 10 minutes. Replace Rear Window Defogger Switch. 6. To bench test relay: a. Using a jumper wire connect a 12 volt batter supply, apply voltage to Pin 3 and 4. Ground Pin 2. b. Follow the above procedures except Step 2 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation Heated Glass Element Switch: Description and Operation SYSTEM OPERATION The rear window defogger switch is a control switch and timer relay integrated into a single panel mounted assembly. Actuating the switch energizes the circuit which allows current to flow through the grid lines. Upon initial actuation for approximately eight to ten minutes, or until either the switch or ignition is turned off. An indicating lamp illuminates a lens inlaid in the control switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Page 6680 Heated Glass Element Switch: Testing and Inspection The rear window defogger switch may be tested in- vehicle or bench tested. In vehicle testing is accomplished in the following manner: 1. Remove the switch from the instrument panel but leave the switch connected. 2. Turn the ignition switch ON. Rear Window Defogger Switch Rear Window Defogger Switch-Export 3. Using a voltmeter, check for battery voltage at Pin 3 and Pin 4. a. If OK, go to Step 4. b. If NOT OK, check fuse 8 in fuse block and the 30 Amp maxi fuse in the Power Distribution Center (PDC). If fuses are OK, check wiring circuit. 4. Check Pin 5, with switch in the ON position there should be battery voltage and no voltage in the OFF position. a. If OK, go to Step 5. b. If NOT OK, no voltage in the ON position or voltage in the OFF position. Replace the switch/relay module. 5. Press switch to ON position. The indicator lamp should come on and remain on for approximately 10 minutes. If the indicator lamp fails to light or no voltage is present for approximately 10 minutes. Replace Rear Window Defogger Switch. 6. To bench test relay: a. Using a jumper wire connect a 12 volt batter supply, apply voltage to Pin 3 and 4. Ground Pin 2. b. Follow the above procedures except Step 2 Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation Power Window Switch: Description and Operation CIRCUIT OPERATION Master Window Switch (Left Window Operation) When the window switch is moved to the window DOWN position, voltage is supplied on the F21 circuit through the CLOSED contacts in the switch to the Q21 circuit. The Q21 circuit connects from the switch to the left front window motor. Grounding is provided on circuit Q11 from the motor back to the switch. The ground is passed through the switch to the Z8 circuit. The Z8 circuit goes to its grounding point. When window UP operation is selected, the power and ground circuits are reversed. Circuit Q11 is the feed and circuit Q21 is the ground. Master Window Switch (Right Window Operation) When the window switch is moved to the window DOWN position, voltage is supplied on the F21 circuit through the CLOSED contacts in the switch to the Q26 circuit. The Q26 circuit connects from the master switch to the right window switch. A BUS bar internal to the right switch passes the voltage through the switch to circuit Q22. Circuit Q22 connects from the switch to the right window motor. Grounding is provided on circuit Q12 from the motor back to the right switch. The ground is passed through the switch on a BUS bar to circuit Q16. Circuit Q16 then goes to the master switch. The ground is passed through the switch to the Z8 circuit. The Z8 circuit attaches to its grounding point. When window UP operation is selected, the power and ground circuits are reversed. Circuits Q12 and Q16 are the feeds and circuits Q22 and Q26 are the grounds. Right Window Switch Operation When the window switch is moved to the window DOWN position, voltage is supplied on the F21 circuit through the CLOSED contacts in the switch to the Q22 circuit. The Q22 circuit connects from the switch to the right front window motor. Grounding is provided on circuit Q12 from the motor back to the switch. The ground is passed through the switch to the Q16 circuit. The Q16 circuit connects from the right switch to the master switch. Ground is passed through the master switch to the Z8 circuit. The Z8 circuit goes to its grounding point. When window UP operation is selected, the power and ground circuits are reversed. Circuit Q12 is the feed and circuit Q22 is the ground. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Helpful Information Power Window Switch: Testing and Inspection Helpful Information - Check the 40 Amp fuse located in the PDC. - Check the 30 Amp circuit breaker located behind the fuse block. - Check the ground at the instrument panel left center support. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Helpful Information > Page 6686 Power Window Switch: Testing and Inspection Power Window Switch Test Driver Side Window Switch Continuity Test Passenger Side Window Switch Continuity Test Remove the switch from its mounting, refer to the Window Switch Removal and Installation procedures. Using an ohmmeter, refer to the test procedure, Driver Side or Passenger Side Window Switch Continuity Test to determine if continuity is correct. If the results are not obtained, replace the switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 6687 Power Window Switch: Service and Repair REMOVAL Switch Removal 1. Using a flat tool, insert tool in the slot on the bottom of the switch bezel. 2. Pry the bezel from the door trim panel. 3. Disconnect wire connector from switch. 4. Remove switch by releasing the tabs from bezel. INSTALLATION - For installation, reverse above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Testing and Inspection Power Window Motor: Testing and Inspection 1. Remove door trim panel. 2. Connect positive (+) lead from a test battery to either of the two motor terminals. 3. Connect negative (-) lead from test battery to remaining motor terminal. 4. The motor should now rotate in one direction to either move window up or down. a. If window happens to already be in full UP position and motor is connected so as to move it in UP direction no movement will be observed. b. Likewise, motor connected to move window in DOWN direction no movement will be observed if window is already in full DOWN position. c. Reverse battery leads in Step 2 and Step 3 and window should now move. If window does not move, remove motor. See for motor removal from vehicle. 5. If window moved completely up or down, the test leads should be reversed one more time to complete a full window travel inspection. 6. If window does not move, check to make sure that it is free. 7. It is necessary that the window be free to slide up and down in the glass channels. If the window is not free to move up and down, the window lift motor will not be able to move the glass. 8. To determine if the glass is free, disconnect the regulator from the glass lift plate. Remove the two attaching nuts, and slide the window up and down by hand. This check can not be made on a four door vehicle. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Testing and Inspection > Page 6692 Power Window Motor: Service and Repair 2 DOOR WINDOW MOTOR WARNING: DO NOT HAVE ANY HANDS OR FINGERS IN SECTOR GEAR AREA WHERE THEY CAN BE PINCHED BY SMALL MOVEMENTS OF REGULATOR LINKAGE. REMOVAL 1. Move the window to the full-up position, if possible. 2. Remove door trim panel and window regulator. WARNING: FAILURE TO CLAMP THE SECTOR GEAR TO THE MOUNTING PLATE WHEN REMOVING THE MOTOR CAN RESULT IN INJURY. 3. Secure the sector gear and mounting plate with a C clamp or similar clamping tool. This will prevent a sudden and forceful movement of the regulator when the motor is removed. 2 Door Motor Removal 4. Remove three mounting screws that hold motor gearbox to regulator. 5. Remove motor from regulator. INSTALLATION 1. Install new motor on regulator by positioning motor gearbox so that it engages regulator sector teeth. 2. A slight rotational or rocking movement may be necessary to bring three motor gearbox screw holes into proper position. 3. Install three gearbox screws and one tie down bracket screw, if applicable. Tighten to 5.6 to 8 N.m (50 to 70 in. lbs.) torque. 4. Install regulator, using the switch, test operation of motor. 4 DOOR WINDOW MOTOR REMOVAL 1. Move the window so it is not in the full up or down position, if possible. 2. Remove door trim panel. 3. Disconnect wiring connector from motor. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Testing and Inspection > Page 6693 4 Door Motor Removal 4. Remove the three nuts attaching the window regulator motor/housing to the door inner panel. This will allow the motor/housing to be moved to the lower door inner panel opening since the cables will flex. 5. Turn the motor/housing to gain access to the three nuts attaching the motor to the housing. 6. Remove the three nuts attaching the motor to the housing. 7. Remove the motor from the housing. Be careful not to pull the cable drum from the housing, as the motor shaft will tend to pull the drum with it. INSTALLATION For installation, reverse above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation Power Window Switch: Description and Operation CIRCUIT OPERATION Master Window Switch (Left Window Operation) When the window switch is moved to the window DOWN position, voltage is supplied on the F21 circuit through the CLOSED contacts in the switch to the Q21 circuit. The Q21 circuit connects from the switch to the left front window motor. Grounding is provided on circuit Q11 from the motor back to the switch. The ground is passed through the switch to the Z8 circuit. The Z8 circuit goes to its grounding point. When window UP operation is selected, the power and ground circuits are reversed. Circuit Q11 is the feed and circuit Q21 is the ground. Master Window Switch (Right Window Operation) When the window switch is moved to the window DOWN position, voltage is supplied on the F21 circuit through the CLOSED contacts in the switch to the Q26 circuit. The Q26 circuit connects from the master switch to the right window switch. A BUS bar internal to the right switch passes the voltage through the switch to circuit Q22. Circuit Q22 connects from the switch to the right window motor. Grounding is provided on circuit Q12 from the motor back to the right switch. The ground is passed through the switch on a BUS bar to circuit Q16. Circuit Q16 then goes to the master switch. The ground is passed through the switch to the Z8 circuit. The Z8 circuit attaches to its grounding point. When window UP operation is selected, the power and ground circuits are reversed. Circuits Q12 and Q16 are the feeds and circuits Q22 and Q26 are the grounds. Right Window Switch Operation When the window switch is moved to the window DOWN position, voltage is supplied on the F21 circuit through the CLOSED contacts in the switch to the Q22 circuit. The Q22 circuit connects from the switch to the right front window motor. Grounding is provided on circuit Q12 from the motor back to the switch. The ground is passed through the switch to the Q16 circuit. The Q16 circuit connects from the right switch to the master switch. Ground is passed through the master switch to the Z8 circuit. The Z8 circuit goes to its grounding point. When window UP operation is selected, the power and ground circuits are reversed. Circuit Q12 is the feed and circuit Q22 is the ground. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Helpful Information Power Window Switch: Testing and Inspection Helpful Information - Check the 40 Amp fuse located in the PDC. - Check the 30 Amp circuit breaker located behind the fuse block. - Check the ground at the instrument panel left center support. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Helpful Information > Page 6699 Power Window Switch: Testing and Inspection Power Window Switch Test Driver Side Window Switch Continuity Test Passenger Side Window Switch Continuity Test Remove the switch from its mounting, refer to the Window Switch Removal and Installation procedures. Using an ohmmeter, refer to the test procedure, Driver Side or Passenger Side Window Switch Continuity Test to determine if continuity is correct. If the results are not obtained, replace the switch. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 6700 Power Window Switch: Service and Repair REMOVAL Switch Removal 1. Using a flat tool, insert tool in the slot on the bottom of the switch bezel. 2. Pry the bezel from the door trim panel. 3. Disconnect wire connector from switch. 4. Remove switch by releasing the tabs from bezel. INSTALLATION - For installation, reverse above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 23-46-97 > Aug > 97 > Door Glass - Scratches Technical Service Bulletin # 23-46-97 Date: 970822 Door Glass - Scratches NO: 23-46-97 GROUP: Body DATE: Aug. 22, 1997 SUBJECT: Door Glass Scratched MODELS: 1995-1997 (PL) Neon SYMPTOM/CONDITION: Door glass is scratched, inner and outer belt stabilizer contacts glass. DIAGNOSIS: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 23-46-97 > Aug > 97 > Door Glass - Scratches > Page 6709 Inspect the door glass, if scratch runs up the glass in line with the stabilizer location (Figure 1 & 2), perform the repair procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-30-10-96 0.7 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves the replacement of the scratched glass and inner and outer belt stabilizer assemblies. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 23-46-97 > Aug > 97 > Door Glass - Scratches > Page 6710 1. Open the door and remove the door trim panel and partial water shield to access glass fasteners. 2. Remove the inner and outer belt weatherstrip. 3. Remove the innerbelt stabilizer (figure 3). 4. Lower the door glass 3/4 way to access glass fasteners. 5. Remove the nuts holding the regulator channel to the door glass. 6. Mark (for installation) and remove the bolts holding the rear guide plate to the glass. 7. Separate the rear guide plate from the glass. 8. Lift the door glass upward and out of opening at the top of the door. 9. Remove the front guide plate from door glass. 10. Remove the outer belt stabilizer(s). If the door being repaired is the front door on the Sedan, there will be one outer belt stabilizer per door. The rear doors on the Sedan and the doors on the Coupe will have two outer belt stabilizers per door (Figure 1). 11. Install the new outer belt stabilizers using the screw and washer removed from the existing outer belt stabilizers and torque to 4.7 Nm (42 in lbs). 12. Loosely install the new window inner belt stabilizer. 13. Install the front guide plate to door glass. 14. Carefully lower the door glass through opening in top of door. 15. Position the front guide plate onto the front glass run. 16. Install the nuts holding the regulator lift channel to the door glass. 17. Use marks made in step 6 to position the rear guide plate onto door glass and install bolts. 18. Roll door glass up, adjust and tighten inner door glass stabilizer. Install inner and outer belt weatherstrips. 19. Tighten window inner and outer door belt weatherstrips. 20. Install door trim panel and water shield. 21. Adjust the door glass as needed following the procedure provided in the 1997 Neon Service Manual (Publication No. 81-270-7025) page 23-47. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 23-46-97 > Aug > 97 > Door Glass - Scratches Technical Service Bulletin # 23-46-97 Date: 970822 Door Glass - Scratches NO: 23-46-97 GROUP: Body DATE: Aug. 22, 1997 SUBJECT: Door Glass Scratched MODELS: 1995-1997 (PL) Neon SYMPTOM/CONDITION: Door glass is scratched, inner and outer belt stabilizer contacts glass. DIAGNOSIS: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 23-46-97 > Aug > 97 > Door Glass - Scratches > Page 6716 Inspect the door glass, if scratch runs up the glass in line with the stabilizer location (Figure 1 & 2), perform the repair procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-30-10-96 0.7 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves the replacement of the scratched glass and inner and outer belt stabilizer assemblies. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 23-46-97 > Aug > 97 > Door Glass - Scratches > Page 6717 1. Open the door and remove the door trim panel and partial water shield to access glass fasteners. 2. Remove the inner and outer belt weatherstrip. 3. Remove the innerbelt stabilizer (figure 3). 4. Lower the door glass 3/4 way to access glass fasteners. 5. Remove the nuts holding the regulator channel to the door glass. 6. Mark (for installation) and remove the bolts holding the rear guide plate to the glass. 7. Separate the rear guide plate from the glass. 8. Lift the door glass upward and out of opening at the top of the door. 9. Remove the front guide plate from door glass. 10. Remove the outer belt stabilizer(s). If the door being repaired is the front door on the Sedan, there will be one outer belt stabilizer per door. The rear doors on the Sedan and the doors on the Coupe will have two outer belt stabilizers per door (Figure 1). 11. Install the new outer belt stabilizers using the screw and washer removed from the existing outer belt stabilizers and torque to 4.7 Nm (42 in lbs). 12. Loosely install the new window inner belt stabilizer. 13. Install the front guide plate to door glass. 14. Carefully lower the door glass through opening in top of door. 15. Position the front guide plate onto the front glass run. 16. Install the nuts holding the regulator lift channel to the door glass. 17. Use marks made in step 6 to position the rear guide plate onto door glass and install bolts. 18. Roll door glass up, adjust and tighten inner door glass stabilizer. Install inner and outer belt weatherstrips. 19. Tighten window inner and outer door belt weatherstrips. 20. Install door trim panel and water shield. 21. Adjust the door glass as needed following the procedure provided in the 1997 Neon Service Manual (Publication No. 81-270-7025) page 23-47. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 23-46-97 > Aug > 97 > Door Glass - Scratches Technical Service Bulletin # 23-46-97 Date: 970822 Door Glass - Scratches NO: 23-46-97 GROUP: Body DATE: Aug. 22, 1997 SUBJECT: Door Glass Scratched MODELS: 1995-1997 (PL) Neon SYMPTOM/CONDITION: Door glass is scratched, inner and outer belt stabilizer contacts glass. DIAGNOSIS: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 23-46-97 > Aug > 97 > Door Glass - Scratches > Page 6726 Inspect the door glass, if scratch runs up the glass in line with the stabilizer location (Figure 1 & 2), perform the repair procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-30-10-96 0.7 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves the replacement of the scratched glass and inner and outer belt stabilizer assemblies. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 23-46-97 > Aug > 97 > Door Glass - Scratches > Page 6727 1. Open the door and remove the door trim panel and partial water shield to access glass fasteners. 2. Remove the inner and outer belt weatherstrip. 3. Remove the innerbelt stabilizer (figure 3). 4. Lower the door glass 3/4 way to access glass fasteners. 5. Remove the nuts holding the regulator channel to the door glass. 6. Mark (for installation) and remove the bolts holding the rear guide plate to the glass. 7. Separate the rear guide plate from the glass. 8. Lift the door glass upward and out of opening at the top of the door. 9. Remove the front guide plate from door glass. 10. Remove the outer belt stabilizer(s). If the door being repaired is the front door on the Sedan, there will be one outer belt stabilizer per door. The rear doors on the Sedan and the doors on the Coupe will have two outer belt stabilizers per door (Figure 1). 11. Install the new outer belt stabilizers using the screw and washer removed from the existing outer belt stabilizers and torque to 4.7 Nm (42 in lbs). 12. Loosely install the new window inner belt stabilizer. 13. Install the front guide plate to door glass. 14. Carefully lower the door glass through opening in top of door. 15. Position the front guide plate onto the front glass run. 16. Install the nuts holding the regulator lift channel to the door glass. 17. Use marks made in step 6 to position the rear guide plate onto door glass and install bolts. 18. Roll door glass up, adjust and tighten inner door glass stabilizer. Install inner and outer belt weatherstrips. 19. Tighten window inner and outer door belt weatherstrips. 20. Install door trim panel and water shield. 21. Adjust the door glass as needed following the procedure provided in the 1997 Neon Service Manual (Publication No. 81-270-7025) page 23-47. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 23-014-06 > Mar > 06 > Customer Interest for Window Seal: > 23-46-97 > Aug > 97 > Door Glass - Scratches Technical Service Bulletin # 23-46-97 Date: 970822 Door Glass - Scratches NO: 23-46-97 GROUP: Body DATE: Aug. 22, 1997 SUBJECT: Door Glass Scratched MODELS: 1995-1997 (PL) Neon SYMPTOM/CONDITION: Door glass is scratched, inner and outer belt stabilizer contacts glass. DIAGNOSIS: Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 23-014-06 > Mar > 06 > Customer Interest for Window Seal: > 23-46-97 > Aug > 97 > Door Glass - Scratches > Page 6737 Inspect the door glass, if scratch runs up the glass in line with the stabilizer location (Figure 1 & 2), perform the repair procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-30-10-96 0.7 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves the replacement of the scratched glass and inner and outer belt stabilizer assemblies. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 23-014-06 > Mar > 06 > Customer Interest for Window Seal: > 23-46-97 > Aug > 97 > Door Glass - Scratches > Page 6738 1. Open the door and remove the door trim panel and partial water shield to access glass fasteners. 2. Remove the inner and outer belt weatherstrip. 3. Remove the innerbelt stabilizer (figure 3). 4. Lower the door glass 3/4 way to access glass fasteners. 5. Remove the nuts holding the regulator channel to the door glass. 6. Mark (for installation) and remove the bolts holding the rear guide plate to the glass. 7. Separate the rear guide plate from the glass. 8. Lift the door glass upward and out of opening at the top of the door. 9. Remove the front guide plate from door glass. 10. Remove the outer belt stabilizer(s). If the door being repaired is the front door on the Sedan, there will be one outer belt stabilizer per door. The rear doors on the Sedan and the doors on the Coupe will have two outer belt stabilizers per door (Figure 1). 11. Install the new outer belt stabilizers using the screw and washer removed from the existing outer belt stabilizers and torque to 4.7 Nm (42 in lbs). 12. Loosely install the new window inner belt stabilizer. 13. Install the front guide plate to door glass. 14. Carefully lower the door glass through opening in top of door. 15. Position the front guide plate onto the front glass run. 16. Install the nuts holding the regulator lift channel to the door glass. 17. Use marks made in step 6 to position the rear guide plate onto door glass and install bolts. 18. Roll door glass up, adjust and tighten inner door glass stabilizer. Install inner and outer belt weatherstrips. 19. Tighten window inner and outer door belt weatherstrips. 20. Install door trim panel and water shield. 21. Adjust the door glass as needed following the procedure provided in the 1997 Neon Service Manual (Publication No. 81-270-7025) page 23-47. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > Page 6739 Wiper Switch: Service and Repair REMOVAL Upper Shroud Removal 1. Remove three screws holding steering column shroud and remove upper half of shroud. 2. Remove mounting screw on switch and remove switch. 3. Disconnect wire harness connector from switch. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection Wiper Switch: Testing and Inspection Wiper Switch Test To test the switch, first disconnect the switch wires from the body wiring in the steering column. Using an ohmmeter, test for continuity between the terminals of the switch, as indicated. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 6745 Wiper Switch: Service and Repair REMOVAL Upper Shroud Removal 1. Remove three screws holding steering column shroud and remove upper half of shroud. 2. Remove mounting screw on switch and remove switch. 3. Disconnect wire harness connector from switch. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair Windshield Washer Pump: Service and Repair REMOVAL 1. Raise vehicle on hoist. 2. Disconnect the wire connector from the reservoir pump. 3. Disconnect the washer hose at the pump and drain the reservoir. Washer Pump 4. Gently pry pump away from reservoir and out of grommet. Care must be taken not to puncture reservoir. 5. Remover rubber grommet from reservoir and throw away. INSTALLATION - For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair Windshield Washer Reservoir: Service and Repair REMOVAL Filler Neck Removal 1. Remove filler neck. 2. Raise vehicle on hoist. Reservoir Removal 3. Disconnect the wire connector from the reservoir pump. 4. Disconnect the washer hose at the pump and drain the reservoir. 5. Remove fastener from reservoir. 6. Remove the reservoir through fender opening. INSTALLATION - For installation, reverse the above procedures. Tighten the reservoir screw to 2.2 to 3.3 N.m (20 to 29 in.lbs.) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation Windshield Washer Spray Nozzle: Description and Operation SYSTEM OPERATION Windshield Washer Nozzle Fig.8 Windshield Washer Pattern - Typical This model is equipped with two hood mounted washer nozzles. Each nozzle emits two streams into the wiper pattern. If the nozzle performance is unsatisfactory they can be adjusted. To adjust insert a pin into the nozzle ball and move to proper pattern. The right and left nozzles are identical. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Page 6755 Windshield Washer Spray Nozzle: Service and Repair REMOVAL 1. Disconnect washer fluid hose at the nozzle. Windshield Washer Nozzle 2. Using a needle nose pliers, squeeze together the locking tabs on the nozzle. 3. Remove nozzle. INSTALLATION 1. Place the nozzle in position and push downward till locking tabs are securely snapped into position. 2. Connect the washer hose and ensure that the hose is not kinked. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments Wiper Arm: Adjustments 1. Cycle the wiper motor into the PARK position. 2. Lift the wiper blade off the windshield and release it. Arm Adjustment 3. The wiper blade heel should be parked within 5 mm of the park line. The park line is mark on the windshield. 4. In the event that the wiper blade tip excessively strikes the cowl screen due to long term normal wear, reposition the wiper blade heel slightly above the park line. Make sure that the wipers are in the PARK position. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments > Page 6759 Wiper Arm: Service and Repair REMOVAL 1. Place the wiper arm/blades in the PARK position and turn ignition OFF 2. Remove arm cap and wiper arm nut. 3. Remove the arm from the pivot using a rocking motion. 4. Clean metal splinters OFF the pivot shafts. INSTALLATION - For installation reverse above procedures. Before installation activate wiper system to ensure the wiper module is in the PARK position. Position wiper arms so that the heel of the blade(s) is on the park line on the windshield. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Customer Interest for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: Customer Interest Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 6773 Wiper Blade: Description and Operation SYSTEM OPERATION Wiper blades, exposed to the weather for a long period of time, tend to lose their wiping effectiveness. Periodic cleaning of the wiper blade is suggested to remove the accumulation of salt and road film. The wiper blades, arms, and windshield should be cleaned with a sponge or cloth and a mild detergent or nonabrasive cleaner. If the blades continue to streak or smear, they should be replaced. The right and left wipers are different blade lengths. The driver side length is 525 mm and the passenger side length is 450 mm. The blades should not be interchanged. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 6774 Wiper Blade: Testing and Inspection Cleaning and Inspection Wiper blades exposed to the weather for a long period of time tend to lose their wiping effectiveness. Periodic cleaning of the wiper blade is recommended to remove the accumulation of salt and road grime. The wiper blades, arms and windshield should be cleaned with a sponge or cloth and a mild detergent or nonabrasive cleaner: If the wiper blades continue to streak or smear, they should be replaced. The wiper blade should run smoothly across the windshield in both directions. The wiper blade should slightly roll over center when the blade reverses direction. A wiper blade insert that has lost flexibility or a wiper arm that has lost spring tension, will cause the blade to skip or chatter across the windshield. If the wiper blades are new and the wiper arm spring tension is OK and a chattering sound is emitted from the wiper(s), the wiper blade is not rolling over center. If this condition exists, refer to the Wiper Arm Alignment. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Cleaning and Inspection Wiper Blade: Service and Repair Cleaning and Inspection Wiper blades exposed to the weather for a long period of time tend to lose their wiping effectiveness. Periodic cleaning of the wiper blade is recommended to remove the accumulation of salt and road grime. The wiper blades, arms and windshield should be cleaned with a sponge or cloth and a mild detergent or nonabrasive cleaner: If the wiper blades continue to streak or smear, they should be replaced. The wiper blade should run smoothly across the windshield in both directions. The wiper blade should slightly roll over center when the blade reverses direction. A wiper blade insert that has lost flexibility or a wiper arm that has lost spring tension, will cause the blade to skip or chatter across the windshield. If the wiper blades are new and the wiper arm spring tension is OK and a chattering sound is emitted from the wiper(s), the wiper blade is not rolling over center. If this condition exists, refer to the Wiper Arm Alignment. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Cleaning and Inspection > Page 6777 Wiper Blade: Service and Repair Wiper Blade REMOVAL 1. Lift wiper arm to over center position. Wiper Blade And Element Remove Blade From Arm 2. Remove blade assembly from arm by pushing release tab under arm tip and slide blade away from arm tip. 3. Gently place wiper arm tip on glass surface. INSTALLATION - For installation reverse above procedures. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Cleaning and Inspection > Page 6778 Wiper Blade: Service and Repair Wiper Blade Element REMOVAL 1. Lift wiper arm to raise blade off glass. Wiper Blade And Element Remove Blade From Arm 2. Remove blade assembly from arm by pushing release tab under arm tip and slide blade away from arm tip. Gently place wiper arm tip on glass surface. Windshield Wiper Blade Element 3. Remove wiping element from blade assembly. Pull stopper, of the rubber element, out of the end claw together with vertebra (metal rails). INSTALLATION Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Cleaning and Inspection > Page 6779 - For installation reverse the above procedures. Check that the element and vertebra are through all claws and the final claw is locked in the stopper. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Wiper Motor Diagnosis Chart Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6784 Wiper Motor: Component Tests and General Diagnostics WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, SEE AIR BAGS AND SEAT BELTS/AIR BAG Whenever a wiper motor malfunction occurs, verify that the wire harness is properly connected start normal diagnosis and repair procedures. Refer to Wiper Motor Test. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Page 6785 Wiper Motor: Service and Repair REMOVAL Wiper Motor And Linkage Module 1. Remove wiper arms and blades. 2. Remove the rear hood seal with the cowl top plastic screen. 3. Disconnect motor wire connector at front plenum wall. 4. Remove wiper module mounting screws and remove module. INSTALLATION - For installation reverse the above procedures. Tighten the mounting screws to 7 to 9 N.m (60 to 80 in. lbs.) torque. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and Repair Wiper Motor Linkage: Service and Repair REMOVAL Wiper Motor And Linkage Module 1. Remove wiper module. 2. Disconnect wiper arm linkage, by insert screw driver between ball cap and linkage, then twist the screwdriver and lift straight up on linkage. INSTALLATION - For installation reverse the above procedures. Using pliers or hand press the ball cap straight on to the ball stud. Dodge Neon Workshop Manual (L4-122 2.0L DOHC VIN Y SFI (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection Wiper Switch: Testing and Inspection Wiper Switch Test To test the switch, first disconnect the switch wires from the body wiring in the steering column. Using an ohmmeter, test for continuity between the terminals of the switch, as indicated.